PREAMBLE (NOT PART OF THE STANDARD)

In order to promote public education and public safety, equal justice for all, a better informed citizenry, the rule of law, world trade and world peace, this legal document is hereby made available on a noncommercial basis, as it is the right of all humans to know and speak the laws that govern them.

END OF PREAMBLE (NOT PART OF THE STANDARD)

ISBN 978-0-626-20961-2

SANS 10089-1:2008
Edition 4.3

SOUTH AFRICAN NATIONAL STANDARD
The petroleum industry
Part 1: Storage and distribution of petroleum products in above-ground bulk installations

Published by Standards South Africa
1 dr lategan road groenkloof private bag x191 pretoria 0001
tel: 012 428 7911 fax: 012 344 1568 international code + 27 12
www.stansa.co.za
© Standards South Africa

I

Table of changes

Acknowledgement

Standards South Africa wishes to acknowledge the valuable assistance derived from publications of the following organizations:

Advisory Fire Management Council
American Petroleum Institute
American Society for Testing and Materials
BP Southern Africa (Pty) Ltd
British Standards Institution
Caltex Oil (SA) (Pty) Ltd
Engen Petroleum Limited
European Petroleum Organizations (European Technical Cooperation)
Institute of Petroleum (UK)
International Oil Tanker Terminal Safety Group
National Fire Protection Association International (USA)
The Associated Octel Company Limited (London)

Foreword

This South African standard was approved by National Committee StanSA TC 5120.18, The Petroleum industry – Equipment and systems, in accordance with procedures of Standards South Africa, in compliance with annex 3 of the WTO/TBT agreement

This document was published in June 2008. This document supersedes SANS 10089-1:2007 (edition 4.2).

A vertical line in the margin shows where the text has been technically modified by amendment No. 3.

This document was written in order to support a specific item of South African regulation and, of necessity, includes references to South African legislation. It therefore might not be suitable for direct application in other jurisdictions where conflicting legislation exists.

Amdt 2

II

SANS 10089 consists of the following parts, under the general title, The petroleum industry.

• – Part 1: Storage and distribution of petroleum products in above-ground bulk installations.
• – Part 2: Electrical and other installations in the distribution and marketing sector.
• – Part 3: The installation of underground storage tanks, pumps/dispensers and pipework at service stations and consumer installations.

Annexes A, B, C, D and E are for information only.

Introduction

Concurrent with the rewriting of this part of SANS 10089, there were far-reaching developments in the marketing of petroleum products. Bulk storage and handling were traditionally handled by the large petroleum companies whose proven integrity in matters of safety and fire engineering have been synonymous with the industry.

Recently, however, there has been a rapid change to the enfranchising of bulk storage, handling and distribution to sales agents who have minimal (if any) experience in or previous exposure to petroleum operations.

During the lifetime of this fourth edition, it can be expected that many more (less qualified) new oil companies will wish to operate, modify, expand or construct distribution facilities. They will have to comply with this part of SANS 10089 and will look to it for guidance.

Nothing prevents any user from opting for a rational design, but any user should be able to use this part of SANS 10089 as a stand-alone code. It draws on the best of previous versions in the South African context and gives guidance with regard to other code systems that could be meaningful in local conditions.

It should be noted that compliance with this part of SANS 10089 does not grant immunity from the relevant legal requirements, including municipal and other by-laws.

Although it is believed that the adoption of this part of SANS 10089 will help reduce the risk of accidents, the South African Bureau of Standards cannot accept any responsibility for any kind of damage or alleged damage in or about premises, areas or vehicles to which this part of SANS 10089 has been applied.

1

Contents

3

4

The petroleum industry

Part 1:
Storage and distribution of petroleum products in above-ground bulk installations

1 Scope

1.1

This part of SANS 10089 covers the layout and design of petroleum bulk depots, and the installation of equipment of the types normally used for the handling, storage and distribution of petroleum products and their derivatives, other than equipment that is used for storage and dispensing on consumer premises (including service stations) and for which relevant standards exist.

1.2

A design will meet the requirements of this part of SANS 10089 if it complies with any one of the approved standards listed (see 2.1). However, such a standard shall be applied in its entirety (where applicable). For example, the product classification of one standard cannot be used in combination with the design of another standard.

NOTES

1. Examples of permits to be issued in relation to construction or repair work are given in annex C.
2. Recommendations specific to the handling and storage of liquefied petroleum gas (LPG) are given in SANS 10087-3. The recommended safety distances for the installation of LPG facilities are given in annex D.
3. The design of an interceptor (gravity separator) that has at least three chambers is described in annex B.

2 Normative references

The following normative documents contain provisions which, through reference in this text, constitute provisions of this part of SANS 10089. All documents are subject to revision and, since any reference to a normative document is deemed to be a reference to the latest edition of that document, parties to agreements based on this part of SANS 10089 are encouraged to take steps to ensure the use of the most recent editions of the documents indicated below. Information on currently valid national and international standards can be obtained from Standards South Africa.

2.1 Standards

API RP 2003, Protection against ignitions arising out of static, lightning, and stray currents.

API Spec 5L, Specification for line pipe.

5

API Std 620, Design and construction of large, welded, low-pressure storage tanks.

API Std 650, Welded steel tanks for oil storage.

API Std 2000, Venting atmospheric and low-pressure storage tanks – Nonrefrigerated and refrigerated.

ASME B31.4, Pipeline transportation systems for liquid hydrocarbons and other liquids.

ASTM D 86, Standard test method for distillation of petroleum products at atmospheric pressure.

EN 1361, Rubber hoses and hose assemblies for aviation fuel handling – Specification.

Amdt 1

EN 1765, Rubber hose assemblies for oil suction and discharge services – Specification for the assemblies.

Amdt 1

EN 14015, Specification for the design and manufacture of site built, vertical, cylindrical, flat-bottomed, above ground, welded, steel tanks for the storage of liquids at ambient temperature and above.

Amdt 2

IP method 341⁾, Determination of closed flash point – Pensky-Martens method.

IP method 170¹⁾ Petroleum products – Determination of flash point – Abel closed cup method.

NFPA 11, Standard for low-, medium-, and high-expansion foam systems.

SANS 62-1, Steel pipes – Part 1: Pipes suitable for threading and of nominal size not exceeding 150 mm.

SANS 62-2 (SABS 62-2), Steel pipes – Part 2: Screwed pieces and pipe fittings of nominal size not exceeding 150 mm.

SANS 252, Metallic hose assemblies for liquid petroleum gases and liquefied natural gases.

Amdt 2

SANS 543, Fire hose reels (with semi-rigid hose).

Amdt 1

SANS 1091, National colour standard.

SANS 1128-1 (SABS 1128-1), Fire fighting equipment – Part 1: Components of underground and above-ground hydrant systems.

SANS 1128-2 (SABS 1128-2), Fire fighting equipment – Part 2: Hose couplings, connectors, and branch pipe and nozzle connections.

SANS 1141, Aircraft fuelling hose.

SANS 1142 (SABS 1142), Diesel engines modified for use in hazardous locations (other than in mines).

SANS 1156-1, Hose for liquefied petroleum gas (LPG) – Part 1: Hose used in road and rail transport.

SANS 1186-1, Symbolic safety signs – Part 1: Standard signs and general requirements.

Amdt 1

1) IP test methods are published by the Institute of Petroleum, 61 New Cavendish Street, London W1M8AR, England.

6

SANS 1475-1, The production of reconditioned fire-fighting equipment – Part 1: Portable rechargeable fire extinguishers.

SANS 1518, Transport of dangerous goods – Design requirements for road vehicles and portable tanks.

Amdt 2

SANS 1522, Fire extinguishing powders.

SANS 1910, Portable refillable fire extinguishers.

Amdt 2

SANS 10085-1, The design, erection, use and inspection of access scaffolding – Part 1: Steel access scaffolding.

Amdt 2

SANS 10086-1, The installation, inspection and maintenance of equipment used in explosive atmospheres – Part 1: Installations including surface installations on mines.

SANS 10089-2, The petroleum industry – Part 2: Electrical and other installations in the distribution and marketing sector.

SANS 10108, The classification of hazardous locations and the selection of equipment for use in such locations.

SANS 10114-1, Interior lighting – Part 1: Artificial lighting of interiors.

SANS 10121, Cathodic protection of buried and submerged structures.

SANS 10123 (SABS 0123), The control of undesirable static electricity.

SANS 10140-3, Identification colour markings – Part 3: Contents of pipelines.

SANS 10142-1, The wiring of premises – Part 1: Low-voltage installations.

Amdt 1

SANS 10228, The identification and classification of dangerous goods for transport.

SANS 10229-1, Transport of dangerous goods – Packaging and large packaging for road and rail transport – Part 1: Packaging.

Amdt 2

SANS 10231 Transport of dangerous goods – Operational requirements for road vehicles.

SANS 10232-1, Transport of dangerous goods – Emergency information systems – Part 1: Emergency information system for road transport.

SANS 10233 (SABS 0233), Transportation of dangerous goods – Intermediate bulk containers.

SANS 10263 (SABS 0263), The warehousing of dangerous goods – Enclosed storage areas and covered and uncovered outdoor storage yards.

SANS 10400 (SABS 0400), The application of the National Building Regulations.

2.2 Other publications

IATA Regulations. International Air Transport Association.

IMDG, International maritime dangerous goods code. International Maritime Organization.

International safety guide for oil tankers and terminals. Distributed on behalf of the International Oil Tanker Terminal Safety Group by the Institute of Petroleum (61 New Cavendish St, London W1M8AR).

7

Major hazard installation regulations. Part of the South African Occupational Health and Safety Act, 1993 (Act No. 85 of 1993).

OCTEL Lead alkyl antiknock compounds. The Associated Octel Company Limited (23 Berkeley Square, London W1X6DT).

Spoornet Manual on Dangerous Goods – Requirements concerning the packing, acceptance, transportation and delivery of dangerous goods. Transnet Limited, Johannesburg.

3 Definitions

For the purposes of this part of SANS 10089, the following definitions apply:

3.1
acceptable

acceptable to the authority administering this standard, or to the parties concluding the purchase contract, as relevant

Amdt 2

3.2
accredited person

a person registered in terms of regulation 9 of the Occupational Health and Safety Act, 1993 (Act No. 85 of 1993), as an electrical tester for single phase, an installation electrician or a master installation electrician

3.3
approved

approved by the appropriate approving authority

3.4
approved apparatus

explosion-protected equipment that has been submitted to the appropriate approving authority for examination and testing and for which a certificate of approval for a prescribed application has been issued

3.5
approving authority

the appropriate of the following:

1. in terms of the Occupational Health and Safety Act, 1993 (Act No. 85 of 1993), the Chief Inspector;
2. in terms of the Mine Health and Safety Act, 1996 (Act No. 29 of 1996), the Mine Engineer;
3. in terms of the Trade Metrology Act, 1973 (Act No. 77 of 1973), the Director of Metrology;
4. in terms of the National Water Act, 1998 (Act No. 36 of 1998), the Director-General, Department of Water Affairs; and
5. the local authority concerned.

3.6
blanketing

the technique of maintaining an atmosphere that is either inert or fuel-enriched in the vapour space of a container or vessel

Amdt 1

8

3.7
boiling point

the temperature at which a liquid exerts a vapour pressure of 101,3 kPa. Where an accurate boiling point is not available for the material in question, or in the case of mixtures that do not have a constant boiling point, for the purposes of this part of SANS 10089, the 10 % point of distillation determined in accordance with ASTM D 86 can be taken as the boiling point of the liquid

3.8
breathing apparatus

an apparatus that allows the wearer to breathe independently of the ambient atmosphere

3.9
buildings

as defined in the National Building Regulations and Building Standards Act, 1977 (Act No. 103 of 1977), as amended

3.10
bulk depot

premises (sometimes referred to as marketing installations or terminals), on which the capacity for the storage of flammable goods or combustible goods (or both) exceeds 200 m³ in above-ground tanks, on which goods are normally received from a refinery or other bulk depot by road, rail, sea or pipeline (or a combination of these), and from which such flammable goods or combustible goods (or both) are delivered

NOTE For above-ground storage of less than 200 m³ for petroleum products, see SANS 10131.

3.11
bunded area

an area bounded by ground contours that confine spillage, or an area surrounded by bund walls

3.12
bund

wall
a wall designed to confine product spillage to the bunded area

3.13
class

the class of petroleum product, based on the following classification:

1. class 0: liquefied petroleum gases
2. class I: liquids, which shall be subdivided as follows:
   • – class IA: liquids that have a closed-cup flash point of below 23 °C and a boiling point of below 35 °C
   • – class IB: liquids that have a closed-cup flash point of below 23 °C and a boiling point of 35 °C or above
   • – class IC: liquids that have a closed-cup flash point of 23 °C or above, but below 38 °C
   • – class II: liquids that have a closed-cup flash point of 38 °C or above, but below 60,5 °C 9
   • – class IIIA: liquids that have a closed-cup flash point of 60,5 °C or above, but below 93 °C
   • – class IIIB: liquids that have a closed-cup flash point of 93 °C or above

NOTES

1. Product classification vary among different standards.
2. Classes II and III constitute the following:

If a class II or a class III combustible liquid should be stored or handled at temperatures above its flash point and at or above its boiling point, special precautions should be taken in both the layout and the operation for such a liquid.

3.14
combustible-gas detector

an instrument used to measure the concentration of flammable vapours in air, up to the lower explosive limits (for example, an explosimeter)

3.15
combustible liquid

a liquid that has a closed-cup flash point of 38 °C or above

3.16
competent person

a person who has the necessary knowledge of and ability with regard to the particular process or type of plant and equipment to which this part of SANS 10089 refers, to render him capable of the work involved

3.17
designated person

a person designated by his employer in terms of the Occupational Health and Safety Act, 1993 (Act No. 85 of 1993)

3.18
effluent

residual water or any other liquid resulting from the use of water for industrial purposes, including any substance suspended therein and any storm water flowing or seeping or being pumped from a site, while such a site is in production or after its temporary closure or permanent abandonment

3.19
explosion-proof

apparatus enclosed in a case that

1. is capable of withstanding an internal explosion of a specific gas or vapour,
2. is capable of preventing the ignition, by arcs, sparks or explosions that occur inside the case, of a specific gas or vapour surrounding the case, and
3. has, when the apparatus is operating, an external temperature such that the surrounding flammable atmosphere cannot be ignited thereby.

NOTE The German term “explosiongeschützt” (frequently translated as “explosion-proof") is used to denote apparatus protected by means other than an explosion-proof case. Such other means include those described as “type e apparatus”, “intrinsically safe apparatus” and “pressurized apparatus".

10

3.20
fire stop

a barrier across pipeline trenches to prevent the spread of fire

3.21
fire wall

a wall intended to prevent the spread of fire or the passage of flammable liquids or gases

3.22
flame arrestor

flame trap
a device used to prevent the passage of flame into or out of an apparatus or equipment

3.23
flame trap

see 3.22.

3.24
flammable

descriptive of a material that is capable of ignition

NOTES

1. The term “inflammable” is not acceptable as a synonym for “flammable”.
2. A flammable liquid is a liquid that has a flash point of below 38 °C. (See also 3.15.)

3.25
flash point

closed-cup flash point
the lowest temperature at which the application of a small flame causes the vapour above a liquid to ignite when the product is heated under prescribed conditions, in a “closed” container (IP method 34 and IP method 170)

3.26
freeboard

the height of a bund wall above the calculated liquid surface

3.27
gas free

descriptive of a vessel, a container or an area that contains an atmosphere in which the concentration(s) of flammable gases or toxic gases (or both) have been certified as being within the prescribed safe limits. (See also 9.10.6 and table 5.)

3.28
gas-free certificate

a certificate, issued by a competent person, that certifies that tests have proved that the concentrations of flammable gases or toxic gases (or both) in the relevant atmosphere are within the prescribed limits (see clause C.1)

3.29
hazardous area

an area in which flammable gases or vapours are or might be present in the air in quantities sufficient to become hazardous

NOTE Hazardous areas are classified as follows (see also SANS 10089-2 and SANS 60079-10):

1. zone 0: An area in which a flammable gas or vapour is continuously present in a concentration within its lower and upper limits of flammability; 11
2. zone 1: an area in which
   1. a hazardous concentration of a flammable gas or vapour occurs intermittently or periodically under normal operating conditions, or
   2. a hazardous concentration of a flammable gas or vapour might occur frequently because of repair operations, or maintenance operations, or leakage, or
   3. breakdown or faulty operation of equipment or processes that might release a hazardous concentration of a flammable gas or vapour, might also cause simultaneous failure of electrical equipment;
3. zone 2: an area in which operations that involve flammable or explosive substances, gases or vapours, or volatile liquids, are so well controlled that an explosive or ignitable concentration is likely to occur only under abnormal conditions.

3.30
hazardous atmosphere

an atmosphere that presents a threat to human life because

1. it contains a flammable gas or vapour in a concentration capable of ignition, or
2. it contains toxic components, or
3. it does not contain sufficient oxygen for breathing.

NOTE The term refers exclusively to danger that arises from ignition, but it should be remembered that a hazardous condition also exists where there is a lack of oxygen or where the atmosphere contains toxic gas or vapour, or an inert gas (such as is sometimes used to purge a tank), in such a concentration as to endanger life.

3.31
inerting

a technique by which a combustible mixture is rendered non-ignitable by addition of an inert gas or a non-combustible dust (See also 3.6.)

Amdt 1

3.32
interceptor

gravity separator
an approved chamber or chambers included in a drainage system and so designed as to permit the passage of effluent but to retain any hydrocarbons that are not miscible in water and that could be carried by the effluent stream.

NOTE Design details for interceptors are given in annex B.

3.33
manifold

one or more header pipes, with branch connections, used for collecting or distributing the products carried in pipelines, pumps or vessels

3.34
maximum allowable working pressure

the maximum pressure, steady state or static, that is permitted anywhere in a tank during normal service

3.35
mobile plant

mobile equipment
plant (or equipment) that is mounted on its own wheels or on tracks that has other facilities that give it mobility

12

3.36
mounded tank

a tank that is above the ground and completely covered by earth, sand or other suitable material

3.37
packed-product facility

a depot for the storage of one or more grades of flammable or combustible products in packages, i.e. a depot in which no product is stored in above-ground or in semi-buried tanks

3.38
permit

a document that is issued by a designated person, or persons, and that permits specific work to be carried out in one or more defined areas

3.39
protection for exposure

fire protection for structures on property adjacent to a liquid petroleum storage site

NOTE Fire protection for such structures should be approved when the structures are located either within the jurisdiction of any public fire department or adjacent to plants that have private fire services capable of providing cooling water streams on the structures.

3.40
respirator

an apparatus that allows the wearer to breathe filtered respirable air (See also 3.8.)

NOTE An atmosphere that is not ignitable is not necessarily respirable.

3.41
responsible engineer

an engineer who is registered in terms of the Engineering Profession Act, 2000 (Act No. 46 of 2000)

3.42
safety gauze

a non-corrodible wire gauze, of nominal aperture size not exceeding 0,5 mm, that is used to prevent the passage of flames into or out of an apparatus, equipment or a building

3.43
safety zone

an area around above-ground tanks and around semi-buried tanks that does not necessarily fall within the premises of the company that operates the site, but over which such company can ensure control and enforcement of safety requirements by a legally binding agreement

3.44
safe atmosphere

an atmosphere that is life-supporting, non-toxic and incapable of being ignited (See 9.10.6 and table 5.)

3.45
semi-buried tank

a tank that is partly in the ground and completely covered by earth, sand or other suitable material

3.46
source of ignition

any means of supplying sufficient energy to ignite a flammable atmosphere

13

3.47
spark arrestor

a device that is capable of preventing the emission of incandescent particles from the exhaust systems of internal combustion engines into the atmosphere

NOTE A spark arrestor is not necessarily a flame trap (flame arrestor).

3.48
tank types

one of the following types of tank, that are commonly used to store liquid petroleum products:

3.48.1
atmospheric tank

a fixed-roof tank, that has a weak roof-to-shell seam, and that is designed to withstand an internal vapour pressure not exceeding (measured at the top of the tank) 3,5 kPa, and that is generally free-venting. (A tank with a vertical cone roof is a typical example.)

NOTE Atmospheric tanks are not designed for storing a liquid at a temperature at or equal to its boiling point.

3.48.2
floating-roof tanks

a type of tank that can be of two designs:

3.48.2.1
open-top floating-roof tank

a tank that is designed to an approved standard (API Std 650 or equivalent), with a pontoon (double-deck metal floating roof) that meets the requirements of the design standard; or

3.48.2.2
internal floating-roof tank

a cone-roof tank with an internal floating roof or a lightweight metal pan, and with roof and eaves ventilation designed in accordance with an approved standard (API Std 650 or equivalent)

3.48.3
low pressure tank

a fixed-roof tank, that has a strong roof-to-shell seam, and that is designed to withstand an internal pressure above 3,5 kPa, but not exceeding 103,4 kPa, measured at the top of the tank (A tank with a hemispheroid top is a typical example.)

3.49
working area

in regard to railway sidings, only that area on each side of the actual staging length of the rail tank car

3.50
unrestricted area

an area of which no part is classified as a hazardous area

3.51
unstable liquid

a liquid that, in the pure state or as commercially produced or transported, will vigorously polymerize, decompose, undergo condensation reaction, or become self-reactive under conditions of shock, pressure or temperature

14

4 Planning of bulk depots

4.1 Design and construction of bulk storage tanks

4.1.1 General

Plans submitted for approval to the approving authority concerned shall be signed by a professional or responsible engineer who thereby certifies that such plans comply with the provisions of this part of SANS 10089. All tanks shall be designed and built in accordance with an approved standard (for example, API Std 650).

4.1.2 Elevated tanks

An elevated tank shall be so designed that it is supported on a structure with a 4 h fire rating.

4.1.3 Vertical tanks

A vertical tank shall consist of not more than one compartment.

4.2 Topography

4.2.1 Safety distances

Hydrocarbons are volatile under certain conditions and their vapours in specific concentrations are flammable. Precautions shall be taken to prevent their ignition and, in the event of fire, to prevent further spread. One facet of a total fire protection package is to reduce the likelihood of a fire by siting facilities at what is considered to be a safe distance from one another. Safety distances do not guarantee protection from fire hazard, but they help to prevent the start of a fire by ensuring that any flammable vapour generated by one facility will diffuse to a concentration well below the lower explosive level (LEL) before it reaches any other facility or area where a source of ignition might exist.

4.2.2 Bulk depot siting

The siting of a bulk depot is of paramount importance, not only from a marketing point of view but also from a fire and security point of view. Cognizance shall be taken of the following:

1. the fall of the ground in relation to residential areas and other risk areas that could be exposed in the event of accidental large-scale spillages;
2. access facilities to and around the site;
3. drainage systems, especially where these link up with the drainage system of the local authority;
4. available water supplies;
5. fire protection, security, and general service facilities in the area, including the fire services’ response time;
6. population densities around the premises;
7. future expansion (see the Major Hazard Installation Regulations of the OHS Act, 1993 (Act No. 85 of 1993)); 15
8. good housekeeping (for example the removal of flammable materials such as rubbish, dry vegetation and oil-soaked soil);
9. the depth of the water table (if it is above the first impermeable layer) and the date of measurement;
10. the soil types down to the first impermeable layer, and the reduced level of the impermeable layer over the site; and
11. the location of any existing boreholes, aquifers or artesian wells within 500 m of the site, and an analysis of the water for hydrogen sulfide and hydrocarbons.

To facilitate future monitoring of the environment, the above information shall be obtained and recorded before construction commences. (See also the Major Hazard Installation Regulations of the OHS Act.)

4.3 Boundaries

In the interests of security, the depot shall be so enclosed as to prevent unauthorized access (see also 5.9.5).

4.4 Tankage layout: minimum safety distances

4.4.1 General

Safety distances of tanks from each other or from property boundaries, public roads, third-party properties, safe areas and other facilities in the depot shall be based on either of two criteria:

1. the minimum distance through which flammable vapours, emitted during normal operational venting to the atmosphere, have to move away from the tank in order to become dispersed and diluted below the lower explosive limit; or
2. the minimum distance over which available protection measures against radiant heat from the tank would remain effective if the tank were to burn.

The safety distances given in 4.4.2 are the consequent minima that are regarded as necessary.

NOTE Annex D gives typical safety distances for an LPG installation.

4.4.2 Safety distances

The minimum shell-to-shell spacing for horizontal tanks that contain class I, II or IIIA liquids shall be as given in columns 3 and 4 of table 1. The minimum for shell-to-shell spacing for vertical floating roof tanks that contain class I, II or IIIA liquids shall be as given in column 2.

16

Amdt 2

In the case of tanks that contain a stable liquid of class I, II or IIIA, at an operating pressure of 17,2 kPa or less, the minimum distance between the tank and any property boundary, public road or building shall be as given in table 2.

17

In the case of tanks that contain a stable liquid of class I, II or IIIA, at an operating pressure exceeding 17,2 kPa, the minimum distance between the tank and any property boundary, public road or building shall be as given in table 3.

Amdt 2

18

In the case of tanks that contain a class IIIB liquid, the minimum distance between the tank and any property boundary, public road or building shall be as given in table 5.

The minimum distance between a tank and the toe of the inside of a bund wall shall be at least 1,5 m.

19

Figure 1 — Typical bulk storage installation showing safety distances

20

Figure 1 (concluded)

21

4.4.3 Normal venting for above-ground tanks

4.4.3.1 General

All atmospheric storage tanks shall be adequately vented to prevent, in the case of a cone-roof tank, the development of a vacuum or pressure that could distort the roof, or in the case of other atmospheric tanks, the design pressure from being exceeded as a result of filling, emptying, and temperature changes. Protection shall be provided to prevent the overpressure in any pump from being discharged into the tank or vessel where the pump discharge pressure can exceed the design pressure of the tank.

4.4.3.2 Normal venting

Normal vents shall comply with the requirements of an approved standard, such as API Std 2000, or another acceptable standard, and shall be of size at least the same as that of the filling or withdrawal connection (whichever is the larger), but in no case shall the nominal inside diameter be less than 30 mm.

4.4.3.3 Vent flow

In the case of a tank or pressure vessel that has more than one fill or withdrawal connection, and where simultaneous filling and withdrawal can take place, the vent size shall be based on the maximum anticipated simultaneous flow.

4.4.3.4 Vent outlets

The outlets of all vents and vent drains on tanks that are equipped with venting to permit pressures from exceeding 17,2 kPa shall be arranged to discharge in such a way as to prevent localized overheating of, or flame impingement on any part of the tank, should vapours from such vents ignite.

4.4.3.5 Venting of tanks

Tanks and pressure vessels for storing class I liquids could be equipped with venting devices that are normally closed except when venting to pressure or vacuum conditions. Tanks and pressure vessels for storing class IA, IB and IC liquids shall be equipped with venting devices that are normally closed except when venting under pressure or vacuum conditions, or with listed flame arrestors. Tanks for storing class I liquids equipped with blankets shall be free venting.

Tanks for storing class II or class III petroleum products could be fitted with open vents.

Pressure and vacuum vents or open vents should not be fitted with fine mesh gauze (less than 6 mm) that is liable to become clogged with dust, dirt or ice and impair venting capacity. However, where such vents are equipped with screens to prevent the entry of foreign matter, the screen shall be of aperture size at least 6 mm.

4.4.4 Emergency venting

4.4.4.1

Every above-ground tank shall have some form of approved emergency venting that will relieve excessive internal pressure in the event of exposure to fire.

4.4.4.2

In the case of vertical tanks, emergency venting could be provided by a floating roof or, if the tank has a fixed roof, by a weak roof-to-shell seam that will fail before any other seam or plate of the tank shell or bottom.

22

4.4.4.3

If emergency venting is provided by means of pressure relieving vents, the venting capacity of normal vents together with emergency vents should be sufficient to prevent failure of, in the case of a vertical tank, the shell or bottom or, in the case of a horizontal tank, of the shell or ends.

4.4.4.4

The emergency venting capacity provided shall be in accordance with an approved standard, such as API Std 2000.

4.5 Tank farms and bunding

4.5.1 General

Spillages and fires that involve bulk storage tanks could pose a risk to the depot, adjoining property, the community and the environment. The general purpose of tank farms and bunding is to limit, contain, divert, minimize and manage the impact of spillages and fires.

The design should consider the optimization of tank farm and bunding sizes in conjunction with fire-fighting requirements of the tank farm and its limitations. The design should also consider the risk of pollution to surface and ground water, soil and environment.

NOTE In certain situations, the equipment required to extinguish a fire cannot be justified by the economic consequences of the fire alone. If, by allowing the fire to burn, the risk to people, the environment and property lying outside the restricted area is not increased, the approving authority need not consider the capability to extinguish a fire to be a requirement.

4.5.2 Spillage control

Spillage control can be provided by remote impounding, impounding around tanks, bunding or by a combination of all three.

In both types of impounding, the impoundment area shall be protected by adequately designed systems to prevent the contamination of ground water if such a risk exists.

4.5.2.1 Impounding around tanks by bunding

Where protection of adjoining property and waterways is by means of impounding by building bund walls around tanks, such bunding shall comply with the following:

1. A slope of at least 1:100 away from the tank shall be provided for at least 15 m or the distance to the bund wall toe, whichever is less.
2. The volumetric capacity of the bunded area shall be not less than the greatest amount of product that can be released from the largest tank in the bunded area, assuming a full tank. To allow for the volume occupied by the tanks, the capacity of the bunded area that encloses more than one tank shall be calculated after the volume of all the tanks, other than the largest tank, below the height of the bund wall has been deducted.
3. To permit access, the outside toe of the bund wall at ground level shall be no closer than 3 m to any property boundary that is or can be built upon.
4. Walls of the bunded area shall be of earth or concrete, and shall be designed to be liquid-tight and to withstand a full hydrostatic head of water. Earthen walls of height 1 m or more shall have a flat section, not less than 0,6 m wide at the top. The slope of an earthen wall shall not exceed the angle of repose of the material of which the wall is constructed.

   In the case of tanks that contain liquids of class I, II or III, and that are situated in porous soils, bunded areas shall receive special treatment to prevent the seepage of spilled hazardous liquids to low-lying areas or waterways. (See also 4.9 and 5.9.)

   23
5. Except as provided for in (f) below, the wall height of the bunded area shall be restricted to 1,8 m.
6. Bund walls shall be permitted to be higher than the general maximum of 1,8 m where adequate provisions are made for normal access and for the necessary emergency access to tanks, valves and other equipment. A safe exit from the bunded area shall also be provided.

   NOTES

   1. Where the average height, measured from the interior grade, of a bund that contains class I liquids exceeds 3,6 m, or where the distance between any tank and the top inside edge of a bund wall is less than the height of the bund wall, provision shall be made for normal operation of valves and for access to the tank roof without entry below the top of the bund. It should be possible to meet these provisions through the use of remote-operated valves, elevated walkways, or similar arrangements.
   2. Piping that passes through bund walls should be designed to prevent excessive stress as a result of settlement of the soil or exposure to fire.
7. The minimum distance between a tank and the toe of an interior bund wall shall be at least 1,5 m.
8. Each bunded area that contains two or more vertical tanks shall be subdivided at least by intermediate bund walls or by drainage channels, to prevent spills from one tank from endangering adjacent tanks within that bunded area.

NOTES

1. Whenever two or more tanks that contain class I liquids, and of which one is of diameter exceeding 45 m, are located in a common bunded area, intermediate bund walls should be provided between adjacent tanks to hold at least 10 % of the capacity of the tank so enclosed, and not including the volume displaced by the tank.
2. Intermediate bund walls or drainage channels (or both) should be so located between tanks as to take full advantage of the available space with due regard for the capacity of each individual tank. Intermediate bund walls should be of height at least 0,5 m.
3. Where provision is made for draining water from bunded areas, such drains shall be so controlled as to prevent flammable or combustible products from entering natural water courses, public sewers or public drains. Under fire conditions, the controls of such drainage shall be accessible from outside the bunded area.
4. No storage of combustible materials shall be permitted in any bunded area.

4.5.2.2 Remote impounding

Where protection of adjoining property or waterways is by means of drainage to a remote impounding area, such systems shall comply with the following:

1. A slope of at least 1:100 away from the tank and toward the impounding area, shall be provided for at least 15 m.
2. The impounding area shall have a capacity of at least that of the largest tank. Where this is impractical because of area restrictions, partial remote impounding for a percentage of the tank capacity shall be permitted, remote from any tank or adjoining property. Bunding that meets the provisions of 4.5.2.1 shall be provided for the volume that was not provided for by the partial remote impoundment. 24
3. The route to and from the remote impounding system shall be so designed that, in the event of a fire, the tank or the adjoining property is not seriously exposed.
4. The confines of the impounding area shall be so designed that, when the area is filled to capacity, the liquid level is not closer than 15 m to any property boundary that is or can be built on, or to any tank. Where partial remote impounding is used, the level in the partial impoundment shall meet the provisions of this subclause. Any excess volume shall meet the provisions for impounding by bunding as provided for in 4.5.2.1, and the tank spacing shall be determined as for tanks impounded in accordance with 4.5.2.1.

4.5.3 Packed-product facilities (warehouses) and pump slabs

Bund walls are not required around packed-product storage areas, storage buildings, filling sheds or pump slabs. Spillage control shall be provided where product is decanted or pumped.

The floors of packed-product facilities shall not be sunken, since petroleum vapours are difficult to clear from such locations and can accumulate and cause toxic and fire hazards.

4.5.4 Lighting

To facilitate night operations, tank farms shall be provided with adequate artificial lighting facilities that comply with the recommendations given in SANS 10089-2 and SANS 10114-1.

4.6 Location and spacing of buildings

4.6.1 General

All buildings shall comply with the National Building Regulations as contained in SANS 10400.

4.6.2 Administrative buildings

Where possible, administrative buildings should be located in a safe area (preferably near the main gates), with access from the roadway so that visitors to the offices do not have to enter the working area of the depot. The walls of these buildings may form part of the outer boundary of the depot.

4.6.3 Operational facilities

Operational buildings (such as filling sheds and pump slabs) shall be spaced as follows:

1. No filling shed or pump slab that contains class I liquids shall be sited less than 15 m from any part of the outer boundary of the depot if the boundary is constructed of open-type fencing. At points where the open-type fencing is replaced by a solid wall, or if the depot is bounded by a solid wall, this distance may be reduced, but shall be at least 6 m. (See also 5.9.5.)

   In the case of filling sheds for class II petroleum products, the above distances could be reduced to 6 m and 3 m respectively. In the case of class III liquids, no limit need be imposed.

2. Filling sheds and pump slabs where class I petroleum products are handled shall be sited at least 15 m from any building in which work that involves heat is done or where open fires are used (for example, reconditioning shops, tin factories, and soldering sheds). In the case of class II and class III petroleum products, this distance may be reduced to 6 m.

NOTE If the safety distances given in (a) or (b) above cannot be attained, fire walls may be used, subject to approval by the appropriate approving authority.

25

4.6.4 Service buildings

Service buildings do not constitute an inherent petroleum-fire hazard but might include open fires or other similar fire hazards. Service buildings shall be sited in safe areas away from places where products are stored and handled and out of the line of possible vapour travel (at least 15 m away in the case of class I products and at least 6 m away in the case of class II products).

4.6.5 Boiler houses, power plants and fire pump slabs

These buildings shall be so located (in safe areas) that their equipment can be safely operated in the event of a fire.

4.6.6 Buildings on boundaries

The walls of buildings other than buildings for which safety distances are given in 4.6.2, may form part of the boundary of a depot. Any openings in such walls shall have some suitable form of security.

4.7 Roadways

4.7.1 Traffic arrangements

On-site roads shall not be used for parking. Special parking areas shall be allocated for petroleum-carrying vehicles. Parking areas for bulk tankers shall be so designed that a large spill will not endanger the tank farm, buildings or any other structures. If possible, allocate a parking area for private cars, preferably on a part of the site that is remote and separated from operational areas.

Vehicles (other than those normally employed on the premises) shall not be used on on-site roads without the prior approval of the manager or his authorized representative. Suitable lighting is essential for night operations. (See also SANS 10089-2 and SANS 10114-1.)

Where pipelines or cables are routed adjacent to roads, protective kerbing shall be provided. If kerbing cannot be provided, warning posts or fencing shall be provided to prevent accidental damage.

Symbolic safety signs and warning signs shall be provided where necessary. In large depots, the numbering or naming of roads is desirable.

4.7.2 Access for fire-fighting equipment

The effectiveness with which fire-fighting equipment can be used, particularly in the early stages of a petroleum-product fire, depends primarily on the speed with which such equipment can be brought into active use. (See also clause 7.)

4.7.3 Layout

The layout of a depot should embody roadways or all-weather hard-surfaced tracks that give mobile equipment and persons access to hydrants and permit effective and safe use of the equipment, irrespective of the location of the outbreak of the fire or the direction of the wind. All such roads and tracks, exits and entrances to buildings, and access to fire-fighting equipment shall be unobstructed.

Hydrants and fire-fighting equipment shall be so located that they can be approached from different directions, and distinctly marked that they can be easily seen (reflective material is recommended to facilitate visibility at night). Hydrants shall be provided at positions that would enable any fire to be combated, irrespective of the wind direction.

26

4.7.4 Planning

When the layout of a bulk storage depot is being planned,

1. the roads shall be so aligned in relation to the siting of the tanks, plant and buildings that basic operational requirements are complied with, and ease of access is provided for fire-fighting purposes;
2. there shall be no cul-de-sacs;
3. in large bulk depots (i.e. of storage capacity exceeding 150 000 m³), a perimeter road with subsidiary intersecting roads that divide tank compounds or other operational areas or both shall be provided (see also 4.5.2.1(c));
4. a uniform grid plan shall be used when the roadways are being designed;
5. where the approach of vehicles to and from a public highway is controlled by gates, the gates shall be set far enough back from the frontage to enable a vehicle to be halted clear of the highway;
6. adequate turning room shall be provided at junctions and care taken to avoid obstructing the vision of drivers, taking into account the Road Traffic Ordinance, which stipulates a minimum turning radius of 13,1 m for vehicles;
7. roadways shall be constructed suitably and with due regard to the traffic and layout of the plant, and the roadways shall be properly maintained;
8. well-surfaced and well-drained main roads that are capable of accommodating two lines of traffic are recommended;

   NOTE Subsidiary roads may be of single-track width with adequate passing bays, and a lower standard of surfacing and drainage is acceptable.

9. a perimeter road may be sited within the safety distances between tanks and boundaries.

4.8 Railway sidings

The provision and construction of private sidings shall be in accordance with the relevant regulations of Spoornet. (See 4.10.1 and the Spoornet manual on dangerous goods (see 2.2).) Sidings shall be so sited that they cannot be cut off by a fire in another area and that they are accessible for fire-fighting purposes.

The position of the railway track relative to plant and to loading gantries of platforms shall be in accordance with the regulations of Spoornet.

Loading sidings shall be located at least 15 m from the running line used by locomotives (electric or other), and rail tank vehicle staging points shall be located at least 15 m from tank shells, buildings in which work that involves heat is done, important buildings (for example, offices), bulk truck loading racks that handle class I products, package warehouses and filling sheds that contain class I products, and possible fire areas. In the case of package warehouses, filling sheds and bulk loading racks that handle class II and III products only, this distance may be reduced to 6 m (see 4.6 and figure 1).

27

4.9 Drainage and interceptors (see also annex B)

4.9.1 Surface water: general

Drainage shall be planned in accordance with statutory regulations. Every advantage of natural seepage for disposal of surface water shall be utilized. Existing storm-water drains, rivers and streams shall be used to cope with the outflow, although it might be necessary to provide special catchment basins or seepage areas in large plants where heavy precipitation rates (that might temporarily be beyond the capacity of the local system) can be expected.

4.9.2 Surface water (tank farm areas)

Suitable drainage facilities shall be provided to deal with surface water and to dispose of fire-fighting water. The water used to control a fire shall be of an acceptable quality (free from hydrocarbons, solvents, alcohols and any additives) before the water is passed into drains.

Outlets from tank farm areas shall be controlled by means of valves situated outside the bunded areas, because access to these valves might be needed during fire-fighting to release excess cooling water.

The valves shall be kept locked in the closed position at all times unless drainage is taking place under the control of a designated person. The valves shall be clearly identified and marked with the direction of opening.

4.9.3 Containment separation

Where it is necessary to use interceptors to separate contaminants from water, consult the relevant regulations as contained in the National Water Act, 1998, as amended. The local authority by-laws shall be consulted and the collecting system shall be so designed as to minimize the amount of surface water that results from precipitation and normal drainage and that has to be routed through the interceptors (thus avoiding the need for inordinately large interceptors). This is best achieved by providing, where possible, separate systems for surface water and for water from contaminated sources such as tank farms and loading and filling areas. (For design details of an interceptor, see annex B.)

4.9.4 Sewage

Where a local system for the disposal of sewage exists, it is obviously desirable that the drainage system be connected to it, but where this is impracticable, septic tanks or other suitable disposal units should be installed. Consult the regulations of the local authority and investigate the suitability of the ground with a view to the installation of disposal beds. Contamination with product in such systems shall be avoided. Conversely, sewage systems shall not be connected to interceptors. (See also the relevant regulations as contained in the National Water Act, 1998, as amended, and the local authority by-laws.)

4.9.5 Washing of vehicles

All wash-bays shall be so designed that effluent, detergents and contaminated water are contained. Run-off water that contains effluent shall be of such quality that it complies with the relevant regulations of the Department of Water Affairs and with the by-laws of the local authority before the water passes into the relevant drains. Specially designed wetlands can also be considered for this purpose.

28

4.10 Loading and discharging facilities

4.10.1 Planning

In planning the layout of road and rail facilities, safety, the environment and efficiency shall be regarded as the basic considerations. The location of these facilities will be determined by the topography and by the proximity of risks from outside the property.

4.10.2 Safety of personnel

All access ladders and operating platforms to facilitate the handling of hoses, the dipping of tanks and the manipulation of valves shall comply with the OHS Act, 1993.

5 Design and construction of plant, equipment and buildings

5.1 Above-ground tankage

Because of the various types of above-ground tankage that can be constructed, close consideration (based on sound engineering principles and common sense, but within the framework of an approved standard (for example, EN 14015, API Std 620, API Std 650, or equivalent)), shall be given to tankage, especially with regard to foundations, venting (see API Std 2000), earthing (see SANS 10089-2), pipe connections, manholes, stairways, ladders, handrails, gauging equipment, floating roofs, diaphragm roofs, cathodic protection systems and maintenance facilities. (See also the current regulations framed under the OHS Act, 1993, with regard to statutory requirements for earthing, stairways, gangways and ladders.)

Amdt 2

All new vertical tanks shall consist of not more than one compartment and shall incorporate a system that will give early warning of a floor-plate leak.

Elevated tanks shall be supported on structures with a fire rating of at least 4 h.

5.2 Pipelines

Underground water mains need not be constructed of steel but shall be designed to withstand a minimum test pressure of 1,5 times the working pressure.

5.2.1 Design of equipment and construction

All pipes, valves and pipe fittings used shall have been fabricated to an approved code (or equivalent) (see SANS 62-1 and SANS 62-2, ASME B31.4, or API Spec 5L), and shall have a safety factor that is adequate for the conditions of service.

5.2.2 Valves

Inside bunded areas, only valves that are of steel, are fire safe, and that comply with an approved standard shall be used (see also 5.2.1). Elsewhere in the depot, approved cast-iron valves may be used.

Valves shall be designed with a suitable factor of safety relative to the pressures and stresses likely to be met in service, and glands shall be such that they can be repacked without the removal of the valves from service.

Valves of other than the rising spindle type shall incorporate an indicator that shows clearly when they are in the open and the closed positions. Valves used in locations where frost damage can be

29

expected, should be provided with means for draining valve bodies or shall be constructed of mild steel.

Where unidirectional fire-safe valves are installed, they shall be so installed that the contents of the tank are held back.

5.2.3 Pipe runs

5.2.3.1 Above ground

Pipelines over pathways, roadways and platforms shall be supported by gantries, bridges or other approved structures. Provision shall be made to ensure that personnel do not come into contact with hot product lines and steam lines.

In areas where frost is likely to occur, measures to prevent the freezing of water in pipelines shall be provided in the design of the pipelines. Such measures include draining points in pipelines where water could accumulate, insulation of the line or anti-freeze systems.

Where vehicular traffic could damage pipelines, provision shall be made to protect such pipelines (by means of guardrails, safety barriers or other suitable means).

Drains designed and intended for storm water control or effluent control (or both) shall not be used to house pipelines.

5.2.3.2 Below ground

At positions where buried pipelines pass under railways and roadways, and at other points at which heavy loads might be experienced, the pipelines shall be protected from uneven ground settlement. (See also 7.8.5.)

If it is impossible to mark, at ground level, the direct route of a buried pipeline, drawings that give all the important details shall be kept.

NOTE The below-ground installation of product lines should be avoided.

Where pipelines are run in open trenches, the trenches should be either self-draining, or should have fire-stops installed at suitable intervals.

5.2.4 Protection against corrosion

Where necessary, the outer surfaces of above-ground pipelines shall be protected by a suitable coating. All below-ground pipelines shall be protected in an acceptable way with suitable corrosion-resistant materials. If a cathodic protection system is used, it shall comply with SANS 10121.

A cathodic protection system shall

1. be designed in accordance with SANS 10121, and
2. follow the electrical safety requirements of SANS 10089-2, SANS 10108 and SANS 10142-1.

5.2.5 Line identification

Colour markings or other acceptable means shall be used to identify the product or service for which pipelines and valves are intended (see SANS 10140-3) and the relevant oil-marketing company’s colour coding of product pipework). It is recommended that the lines be stencilled at strategic points, for example, FRESH WATER MAIN, SALT WATER MAIN, FOAM, BASE INJECTION, etc. Letters that are clearly legible and of contrasting colour to the colour coding of the pipeline itself shall be used.

30

5.2.6 Testing

Before each completed pipeline is commissioned and, where applicable, before the closing of the trench(es) in which a product pipeline is laid, ensure that the pipeline is properly fabricated and free from leaks by testing it in accordance with the design code employed. It is recommended that all buried pipelines be pressure-tested annually throughout their service life, and provision should be made for this. Pipelines shall be fitted with adequate vent connections, drain connections and fittings to facilitate testing.

Thermal pressure relief shall be provided on all product pipelines.

5.2.7 Flow direction

Pipeline systems shall be so designed, through use of L-port, T-port and non-return valves, that the possibility of flow in unintended directions is minimized.

5.3 Hoses (for product)

5.3.1

Hoses shall be used that comply with the requirements of EN 1361, EN 1765, SANS 252, SANS 1141 or SANS 1156-1 (as relevant), or with an equivalent approved specification, and that are designed for a working pressure at least equal to the maximum working pressure likely to be met in the pipeline system to which the hoses might be connected.

Amdt 2

5.3.2

Materials used for the outer covering of hoses shall be resistant to abrasion and to deterioration arising from contact with petroleum products. Hoses shall be pressure-tested at least once a year at a test pressure of 1,5 times the maximum working pressure, and records of such pressure tests shall be kept and made available for inspections.

5.4 Pumping plant (for product)

5.4.1 General

All pumps for application and intended service in the petroleum industry shall be designed to an approved standard.

5.4.2 Pumps

The type of pump to be used will be determined by the product characteristics and pumping requirements. Preferably use centrifugal pumps of single-stage or multi-stage design for all products except viscous fuel oils. Where positive-displacement pumps can have significant advantages, they may be used. Screw pumps and piston-type pumps are particularly suitable for handling heavy, heated products. Pumps shall be adequately supported. Spill containment shall be provided for all pumps, and shall include suitable drainage.

5.4.3 Pipe manifolds and pumps

Pipe manifolds and pumps shall be protected in an acceptable way from stress induced by the expansion and contraction of pipe lines. Hose connections from manifolds are regarded as a fire risk and shall not be used indiscriminately. Pumps and pump manifolds should preferably not be located inside a bunded area where class I liquids are stored or pumped.

5.4.4 Electrical equipment

Electric motors that are used to drive pumps shall be rated for continuous operation at the maximum power output likely to be required in service. Electric motors and associated equipment located within a hazardous area shall conform to, and be installed in accordance with, the requirements of SANS 10086-1, SANS 10089-2, SANS 10108 and SANS 10142-1.

31

5.5 Loading and unloading of bulk road vehicles and bulk rail vehicles

5.5.1 Loading arrangements

Arrangements for either open or closed loading can be adopted to prevent splash loading. Where top loading arrangements are used, the point of discharge from the loading arm shall be positioned close to the bottom of the tank.

Where bottom loading arrangements are used, an overfill protection method shall be installed to provide control of the quantity delivered to vehicle tanks. (See also the Spoornet manual on dangerous goods (see 2.2)).

5.5.2 Layout

In the layout of road-vehicle loading facilities and rail tank-vehicle loading facilities that handle class I (or class I combined with class II and class III) products, the safety distance shall be at least 15 m. If only class II and class III products are handled, this distance may be reduced to 6 m. (See also 4.8.)

Allow for ease of vehicle access and exit, preferably without the need for reversing. It is preferable to group road-vehicle loading points on islands that are parallel to one another. Such islands shall have suitable protection for the loading equipment.

The area adjacent to a railway siding where petroleum products are loaded or unloaded shall be so graded that a major product spillage will be contained.

Where practicable, adequate earth dikes, channels, etc., to control such a spillage shall be provided. Rail-vehicle loading points shall be located alongside the track at intervals that suit the vehicle dimensions.

Wherever possible, the section of track that serves the rail-vehicle loading facilities shall be reserved for this purpose only. The track and pipelines shall be properly bonded and earthed in accordance with the relevant regulations of Spoornet. (See the Spoornet manual on dangerous goods (see 2.2)).

5.5.3 Road-vehicle loading areas

The loading areas shall be surfaced with materials that are resistant to damage by the product(s) and by fire. The surface shall be so graded that spillage occurring at any one point will not flow under vehicles at any other point. An acceptable method of spillage control shall be provided at all filling points, including spillage containment with sufficient capacity to hold a minimum of two minutes’ flow from the loading point with the largest capacity. The drainage system that is used shall be so connected that it drains the area to an interceptor.

5.5.4 Rail-vehicle loading and unloading areas

These areas shall have permeation values of less than 10^–6 cm/s. Any spillage that occurs, shall be contained and passed through an interceptor for recovery.

At loading facilities, spillage containment shall be provided, with sufficient capacity to hold a minimum of two minutes’ flow from the loading point with the largest capacity. At unloading facilities, spillage containment shall be provided to hold the capacity of the single largest rail vehicle that can be accommodated at the siding.

32

5.5.5 Loading equipment

Loading equipment can be located at ground level or on a platform of a height that suits the transport fleet. Loading equipment shall be so installed that the strain on any metering unit does not exceed the design limit of the unit.

When automatic loading equipment is used, a manually operated shut-off valve for use in an emergency shall be provided away from the risk area.

Where gravity loading methods are used and also where gravity flow to the equipment is possible, each supply line shall be fitted to the loading points with a quick-acting emergency stop-valve located at a safe distance from the loading area.

5.5.6 Platforms

All platforms shall comply with the requirements of the OHS Act, 1993.

5.5.7 Construction materials

Materials that are of adequate strength and that are non-combustible shall be used in the construction of loading structures.

5.5.8 Earthing

Before any connections are made to trucks or rail vehicles and before any flow of the product commences, an electrically continuous path (bond) shall be in place.

The accumulation of static electricity shall be reduced by earthing and bonding the loading or the unloading equipment (or both) in accordance with the recommendations given in SANS 10089-2. (See also SANS 10123.)

5.5.9 Lighting

All lighting shall comply with the requirements of the OHS Act, 1993. Electrical installations shall be in accordance with the recommendations given in SANS 10089-2.

5.6 Ship loading and discharging equipment

Ship loading and discharging facilities shall be designed in accordance with the relevant regulations of Spoornet, Portnet and Petronet and the recommendations given in the International safety guide for oil tankers and terminals (see 2.2). (See also 6.1.)

5.7 Package filling and packaged-oil warehouse buildings

5.7.1 General construction

All buildings shall comply with SANS 10400. Use fire-resistant materials in the construction of buildings and equipment. (See also SANS 10263.)

5.7.2 Spillage

Separator facilities shall be provided to contain any possible spillage and to prevent the spillage from leaking into sewage drains. (See also annex B.)

33

5.7.3 Ventilation

All ventilation in buildings shall comply with the requirements of the OHS Act, 1993. Unless the buildings have open sides, they shall have ventilation openings in opposite sides near the floor and near the roof. (See also SANS 10400 and SANS 10263.)

5.7.4 Service doors, windows and skylights

Where so required by the National Building Regulations (see SANS 10400), alternative means of escape in the event of a fire shall be specified.

5.8 Packed-product storage areas

Packed-product storage areas shall be provided with suitable drainage and measures against flooding. The base of these storage areas shall be constructed from any suitable material that will provide support for the loads to be carried (including those imposed by any mechanical handling equipment to be used). (See also SANS 10263.)

5.9 General site works

5.9.1 Design and construction of bund walls (see also 4.5)

Bund walls shall be constructed of earth or concrete, and shall be liquid-tight. Bunds shall not be covered with any material that will deteriorate under the effects of any petroleum product. All bunds shall be designed by a person qualified in terms of the Engineering Profession Act, 2000 (Act No. 46 of 2000).

Because of the behaviour of other materials in the event of a fire, earthen bund walls or earthen bund walls contained within masonry are preferred. Ensure that earthen bund walls have a flat crown of at least 0,6 m wide and suitable foundations that prevent oil from seeping underneath them and polluting the environment, or from escaping from the bund. If the earth is permeable, and a high risk of contamination of ground water exists, an approved method of sealing shall be provided (e.g. high density poly-ethelene (HDPE) plastic sheeting).

Whenever a bund wall has been breached, the gap shall be made good as soon as possible, and not left open overnight while any tank it encloses has product in it. Pipelines that pass through bund walls shall be wrapped to protect them from corrosion and sealed to prevent leakage of product.

Main bund walls shall be strong enough to withstand the hydrostatic pressure to which they will be subjected if the space within the bund is filled with water. Cognizance shall be taken of the effect of heat exposure under fire conditions.

5.9.2 Bund floors

Permeable bund floors shall be restricted to a coefficient of permeability not exceeding 10^–6 cm/s (in situ).

5.9.3 Railway sidings

Railway sidings shall be constructed, operated and maintained in terms of the private siding regulations of Spoornet. Gates equipped with efficient catches to hold them open when required, shall be provided across railway lines. Prevent gates and fences from picking up electric charges from the rails by so constructing the gates that they cannot touch either running rails or check rails.

Electrical installations and earthing arrangements and provisions for the electrical isolation of private sidings from main-line electrified services shall conform to the regulations of Spoornet. No overhead cable shall cross a siding where rail vehicles are loaded or unloaded.

34

The working area, if it has an impermeable surface, shall have surface drainage on each side of the track or, alternatively, filter drains shall be installed to act as collectors. The drains shall be led to an interceptor via a valved system. Adequate means and procedures for catching and disposing of product from leaks and spills shall be provided.

5.9.4 Drainage interceptors

Drainage interceptors shall be provided on all drainage systems where a spillage could occur. Drainage interceptors shall comply with the requirements of 4.9. For design criteria of an interceptor, see annex B.

5.9.5 Boundaries

Boundary fencing with a total vertical height (from ground level to the top of the fence line, including barbed wire) of at least 2,5 m is required. It shall be of an approved type of unclimbable fencing or walling, and may be of chain-link fencing, steel paling, brick or mass concrete walling, or of the slab-and-post concrete type. It will often be found that more than one type of boundary fencing can be usefully employed at the same depot, for example, chain-link or other open-type fencing for tank compounds, and brick or concrete walling for busy operational areas, particularly where these adjoin a public thoroughfare.

NOTE Where a number of bulk depots that belong to different companies adjoin or are situated within a controlled and fenced area such as a dock, the above stipulations may be relaxed, subject to agreement by the approving authority.

6 Operations

Operating procedures shall comply with the relevant procedures of the General Safety Regulations provided for in the OHS Act, 1993.

6.1 Receiving bulk cargoes from and delivering bulk cargoes to tank vehicles

6.1.1 General

Throughout each unloading or loading operation, a designated person shall be on duty at the depot and a responsible ship’s officer shall be in attendance. Frequent inspection of ship-to-shore hoses and pressure gauges by a person on duty is necessary in order to detect any possible hose leakage.

6.1.2 Regulations

All regulations contained in the International safety guide for oil tankers and terminals, and those of Portnet, the fire authorities, the operating company and the OHS Act, 1993, shall be strictly adhered to. It is recommended that an extract of relevant port and depot regulations be handed to the master of a vessel on arrival.

6.1.3 Communications

An efficient communication system shall be set up between all persons involved in operations, to ensure that cargo-handling operations are safe and efficient, and that immediate action can be taken in the event of an emergency. Where class I and class II products are handled, communication equipment shall be acceptable explosion-proof equipment, and shall comply with the requirements of SANS 10108.

35

6.1.4 Earthing, bonding and insulation

All earthing, bonding and insulation shall comply with the requirements as laid down in SANS 10086-1 and SANS 10089-2 and in the Spoornet manual on dangerous goods (see 2.2).

6.2 Loading and unloading of rail tank vehicles

It is recommended that the entry of rail tank vehicles into a siding and the loading and unloading operations be controlled by a designated person, who shall adhere to the relevant Spoornet regulations contained in the Spoornet manual on dangerous goods (see 2.2). In addition, the following shall be noted:

1. movement of rolling stock within 15 m of a rail tank vehicle that is being loaded or unloaded shall not be permitted, and locomotives that are not approved for use in hazardous areas shall not be permitted to approach closer than 15 m to a loading or unloading point during operations that involve class 0, class I, class II or class III products;
2. a warning notice (symbolic sign) shall be placed near both the loading and the unloading points and shall state the point beyond which locomotives shall not pass;
3. suitable warning notices (symbolic signs) shall be displayed during each loading or unloading operation;
4. a recognized distinctive code of sound signals and lights shall be used during shunting operations;
5. during loading and unloading operations, suitable warning notices shall be conspicuously displayed at the approach to internal sidings. Should the sidings fall outside the depot, the warning notices shall be displayed at both ends of the train;
6. smoking shall only be permitted in designated areas; and
7. splash filling or splash loading shall not be allowed (see SANS 10089-2).

6.3 Loading and unloading of road vehicles

The following general safety rules shall apply during loading and unloading of road vehicles:

1. no vehicle shall be left unattended while loading or unloading is in progress;
2. accidental movement of the vehicle shall be prevented, and it shall be left in a gear that prevents movement;
3. all vehicle engines shall be switched off before loading, and shall not be restarted until all caps, cocks, valves and covers have been closed and secured;
4. no internal combustion engine (other than that of a vehicle specially equipped for transporting, handling, or pumping flammable liquids) shall be closer than 15 m to an area in which class I or class II products are being loaded or unloaded;
5. vehicles awaiting loading shall remain at a safe distance from the loading point;
6. smoking shall only be permitted in designated areas;
7. heated products shall be handled with great care; 36
8. all personnel shall be provided with protective clothing for loading or unloading operations (see the OHS Act, 1993);
9. where operations involve switch loading, safety procedures shall be implemented (see API RP 2003); and
10. splash filling or splash loading shall not be allowed (see SANS 10089-2).

6.4 Containers

Containers used in the petroleum industry vary considerably in type and size. In order to select the type of pack that will be acceptable, it is necessary to consult the OHS Act, 1993, and the publications of the appropriate transportation authority. The publications available at present are:

1. Spoornet manual on dangerous goods – Requirements concerning the packing, acceptance, transportation and delivery of dangerous goods;
2. IATA regulations, relating to the carriage of restricted articles by air; and
3. International Maritime Dangerous Goods Code of the Intergovernmental Maritime Consultative Organization (IMCO).

However, the publications listed above do not always give details of the components of the pack or of its minimum performance level and, in such cases, containers and packs that comply with the requirements of SANS 10229-1 and SANS 10233 (as relevant) shall be used.

Amdt 2

7 Fire precautions and fire control in bulk depots

7.1 General

The protection facilities against fire hazards in bulk depots shall be achieved by good engineering design and construction standards. Safe operational procedures and efficient plant and equipment maintenance shall be such that it is highly improbable that fire will break out.

7.2 Ignition sources

7.2.1

Any device or action that could cause a flame or spark shall not be permitted in restricted areas, unless authorized by an appropriate permit, the stipulations of which shall be strictly adhered to. (See also 7.2.3.)

7.2.2

Sources of ignition include but are not limited to the following:

cutting and welding, electrical sparks, frictional heat or sparks, furnaces, heating equipment, hot surfaces, lightning, open flames, ovens, radiant heat, smoking, static electricity, stray currents and spontaneous ignition.

7.2.3

Welding, cutting and similar spark-producing operations shall not be permitted within the depot premises without an authorized hot-work permit (see 9.1.2 and 9.8).

7.3 Access control

7.3.1 Persons

All points of entry to depots shall be so planned that persons or passenger vehicles that enter or leave the depot can be observed. Unauthorized persons shall not be permitted access to the depots.

37

7.3.2 Locomotives and rolling stock

7.3.2.1

Locomotives shall not be permitted to enter hazardous areas, unless they comply with SANS 1142.

7.3.2.2

Trucks shall not be shunted onto or off sidings during loading and unloading operations. Warning notices (see 7.15) against such shunting shall be displayed near the entrances to sidings during loading or unloading operations.

7.3.2.3

Fly shunting shall be prohibited.

7.4 Housekeeping and vegetation

The site shall be kept free from obstructions and combustible rubbish. Vegetation that is liable to dry out and become a fire hazard shall be kept short and cuttings shall be removed.

7.5 Absorbents

Absorbents are basically recommended for containing spillages. Adequate supplies of absorbents shall be available at all times.

7.6 Work permits

Before any construction, repair, or maintenance work is carried out, the appropriate certificates or work permits (or both) shall be issued in terms of 9.8. (For examples, see annex C.)

7.7 Training (safety organization)

Each facility shall have a safety organization the size of which will depend upon the complexity of the operation.

The safety organization shall advise the management on the technical and legal aspects of safety and shall provide a programme for the improvement of safety performance (training programmes).

As many persons as practicable at each work site shall be given training in the use of the appropriate fire-fighting equipment. All actions shall comply with the relevant section of the OHS Act, 1993.

7.7.1 Safety training

Safety training shall include operational procedures, emergency procedures and safe working practices, information on specific hazards, first aid and fire-fighting, and the proper use of protective equipment such as breathing apparatus. Periodic refresher training shall be maintained.

7.7.2 Emergency plans (on-site and off-site)

Emergency plans shall be prepared to cover foreseeable types of emergencies, which shall cover situations that range from a small incident to one of disaster proportions where considerable assistance from outside organizations is needed. Any emergency plan shall comply with the regulations for major hazard installations as laid down in the OHS Act, 1993.

38

7.8 Scale of fire-fighting equipment

7.8.1 Water requirements

Water requirements shall be calculated on the basis of a full risk assessment, which shall be conducted by the responsible engineer (see 3.41).

Water supplies shall be sufficient for supplying all the devices that could be used simultaneously for the specified time. This includes not only the volume required for foam apparatus, but also water that could be used for other fire-fighting operations, in addition to normal plant requirements. (See annex A.)

7.8.2 Supply rate

The total supply of water for fire-fighting shall be sufficient to supply water at the rate calculated under 7.8.1 for a period of at least 1 h on any approved rational fire-fighting design. When water requirements are being calculated, allowance shall be made for additional water supplies, for example water needed to cool adjacent tanks, etc.

7.8.3 Water pressure

Water shall at all times be supplied to the most remote site location at a running pressure of 1 MPa (10 bar) at the design flow rate.

7.8.4 Pump connections

Suitable fire pump connections shall be provided to facilitate the pressurization of the water reticulation system in order to comply with 7.8.3. All pump connections (electrical or mechanical) shall be compatible with fire-fighting equipment used by the local authorities.

7.8.5 Hydrant mains

Wherever practical, the hydrant main shall be buried to withstand the vehicular traffic (for example, fire tenders). Suitable risers, spaced not more than 90 m apart, sufficient hydrant outlets, and hose connections shall be provided to meet the needs in any potential fire area. Hydrants that serve tank-farm areas shall preferably be of the four-headed pillar type with a riser of minimum diameter 100 mm.

Hydrant outlets and hose connections shall be so sited that they will be at least 15 m from potential fire areas, and shall be compatible with the requirements of the local authority.

7.8.6 Isolating valves

The fire main shall be provided with isolating valves that are so spaced that no damage or repair to the pipe system (exclusive of arteries) will necessitate the shut-down of an artery or of a section of pipe of length exceeding 300 m in any area.

7.8.7 Fire hoses

Fire hoses shall have fittings that are compatible with all the hydrant connections and shall be maintained for the worst-case fire scenario.

7.8.8 Foam applications

Normal finished foam is produced by introducing foam compound into water (usually at a rate of 3 % to 6 %) and then expanding the mixture with air for the type of low-expansion foam compound used. (The expansion factor is about 8 to 1.)

39

The foam may be applied by monitors that deliver it to the seat of the fire or, in the case of tanks, by dry risers or subsurface injection.

In the case of fixed-roof tanks, the application rate of the available mixure (solution) of foam compound and water for fire-fighting with low-expansion foam, can be calculated in litres per minute per square metre of total fire area. As a general rule, 6,5 L/min/m² of fire area will result in the fire being extinguished (see NFPA 11).

Depending on the design of the tank, foam may be applied either by direct projection or by means of dry risers. In the case of floating-roof tanks, it is usual to design fire-fighting facilities that cater for rim-seal fires only.

This is most commonly done by applying low-expansion foam to the seal area. Vaporizing liquid systems are also used, especially in the case of crude-oil tanks. When foam is used, dry risers and foam dams shall be provided for.

An alternative method of applying foam is by injection via the base of a storage tank through product lines or special inlets (see NFPA 11). To avoid foam dilution, it is important to ensure that any injection point is above the water level of the tank bottom. Foams suitable and approved for base injection should be used.

7.8.9 Foam stocks

Sufficient foam compound should be stocked to cater for the largest extinguishable fire in the greater of a fixed-roof tank and the largest possible spill area for 1 h, plus a complete reserve charge to cover the possibility of a second fire. Furthermore, it is recommended that some of the calculated requirements be held in terms of the mutual-aid arrangements between local authorities and industry.

7.8.10 Extinguishers

Conveniently placed hand-held fire extinguishers or large mobile fire extinguishers, or a combination of these, shall be provided, which shall comply with SANS 10400 (see section TT 37).

The servicing of portable fire extinguishers shall comply with the requirements of SANS 1475-1.

7.9 Location and marking of equipment

7.9.1 Location plan

For ready reference in an emergency, a layout plan of the site shall be displayed in an easily accessible location so that authorized persons can have easy access to it. The plan shall indicate the position and the nature of the contents of all product tanks, product pipe lines and valves, as well as the positions of water pipelines, hydrants, fire appliances, the fire control centre, emergency stop buttons, and access routes for fire-fighting equipment to reach all parts of the plant.

The plan shall also indicate the location of fire-fighting equipment and foam storage, including the quality and type of foam stored.

7.9.2 Emergency numbers

A notice on which the telephone numbers of the fire service and other emergency services are clearly recorded, shall be displayed near every telephone, at the control centre and at the gate of the site.

40

7.9.3 Tank identification

All tanks shall have their numbers painted on in two positions, one that is visible from the fire-service access route and the other opposite it, as follows:

1. numerals and letters shall be in colours that contrast with that of the tank shell; and
2. characters shall be of such size as to be clearly visible and identifiable, of minimum height 290 mm and of minimum width 25 mm.

7.9.4 Equipment and hydrant points

All fire points (equipment and hydrant points) shall be clearly identified by the appropriate signs in accordance with SANS 1186-1 or an approved international standard. It is recommended that retro-reflective materials be used for this purpose. (See also 7.11.)

7.10 Fire-fighting equipment

7.10.1 Portable and mobile fire-extinguishers

7.10.1.1

Portable and mobile fire-extinguishers shall comply with an approved standard (for example, SANS 1910).

Amdt 2

7.10.1.2

Dry-chemical powders shall be of a type that complies with SANS 1522 and is compatible with the intended application.

7.10.1.3

All fire-extinguishers shall be protected from the weather.

7.10.2 Fire hoses

7.10.2.1

Fire-fighting hoses shall comply with an approved standard (for example, SANS 543).

7.10.2.2

Hoses shall be inspected at least once every calendar year by a designated person. Hoses found to be defective on inspection shall be replaced or repaired immediately.

NOTE A record should be kept that shows the date of each inspection and is signed by an appointed responsible person. (See also 7.16.4.)

7.10.2.3

Fire-fighting hoses shall be housed or stored in weatherproof containers when not in use.

7.10.3 Couplings

7.10.3.1

Couplings for hoses, branch pipes, nozzles and connectors shall comply with SANS 1128-2.

7.10.3.2

All couplings shall be compatible with the local authority’s fire-fighting equipment.

7.10.4 Hydrants

All hydrants shall comply with SANS 1128-1 and shall be provided with rubber or plastic protective caps.

41

7.10.5 Fire alarms

7.10.5.1

Fire alarms shall be of such volume and tone that they are clearly distinguishable from background noise and are audible, under prevailing wind conditions, anywhere along the perimeter of the site.

7.10.5.2

Where an alarm is electrically powered, an independent source of power shall also be available.

NOTE Hand-cranked or compressed gas units may also be used.

7.10.5.3

An approved means of direct emergency communication with local emergency services shall be available.

7.10.6 Foam concentrates

7.10.6.1

Foam compound shall comply with an approved standard. A knowledge of the compatibility of different foam compounds with one another and with dry chemicals, when used simultaneously in fire-fighting, is essential, since outside bodies, such as the local authority, might use different compounds. Regular quality tests shall be carried out in accordance with the manufacturer’s recommendations.

NOTE It is recommended that low expansion foam is used.

7.10.6.2

Foam compound types shall be suitable for the risk presented by the product on hand. All foam compound containers shall be clearly marked, appropriate to the type of compound. In this regard, expert advice shall be obtained from approved standards or from the manufacturer (or from both) (see SANS 1910 or NFPA 11).

Amdt 1; Amdt 2

7.10.6.3

Foam compound that is corrosive shall be stored in suitable containers.

7.11 Colour identification of fire-fighting equipment

All fire-fighting equipment shall be painted a distinctive red (A11 signal red or A14 poppy red, see SANS 1091). Notices shall be displayed in accordance with the requirements of SANS 1186-1 and the location of equipment that is not visible shall be clearly indicated. (See also 7.9.4.)

7.12 Employees for fire-fighting

All selected key employees shall be trained and remain competent to deal with all possible emergencies and shall be conversant with the principles of fire-fighting and the operation of the fire-fighting equipment provided in their work environment.

An adequate number of employees shall be trained to stand in for absent trained key employees during periods of leave (including absences due to sickness) and on public holidays.

Records shall be kept of all training, as required by the OHS Act, 1993. (See also 7.16.4.)

7.13 Fire drills

After key personnel have been trained, fire drills shall be conducted regularly to maintain a competence level. Records shall be kept of all fire drills, as required by the OHS Act, 1993. (See also 7.12.)

42

7.14 Co-operation with the local fire authorities

It is essential to co-operate closely with the local fire authorities and to ensure that the fire brigade knows in advance the layout of the depot, what equipment and facilities are available, where they are located, and how they are used.

It is essential that an adequate joint plan of action in the event of a fire or other emergency be agreed upon in advance with the fire authority concerned, taking into account aspects such as the nature of the product stored and special risks (if any) that exist in the depot. (See also 7.16.3.)

7.15 Warning notices and signs

Warning notices or symbolic safety signs (or both) shall be displayed at all entrances to hazardous areas, in accordance with the requirements of SANS 1186-1.

7.16 Testing and records

7.16.1

All portable and mobile fire-exinguishers shall be examined and tested periodically in accordance with SANS 1475-1 or the manufacturer’s instructions.

7.16.2

All fire-fighting equipment and systems shall be inspected once every calendar year by a competent person.

7.16.3

A fire practice shall be carried out once every calendar year, and shall include the local fire department’s personnel and appliances. (See also 7.14.)

7.16.4

Records of all inspections, tests and practices shall be kept by the designated person, and any shortcomings shall be rectified as soon as possible. These records shall be made available for inspection at any time during normal working hours. (See also 7.10.2.)

8 Protection and welfare of personnel

8.1 General

It is assumed that the layout of the depot, the type of plant and equipment installed, and the methods of operation are fully in accordance with the relevant recommendations given in this part of SANS 10089, and that familiarity and general compliance with ordinances, the applicable regulations framed under the OHS Act, 1993, and any other applicable regulations are ensured.

All accidents and dangerous occurrences shall be reported to the designated person or safety representative, who shall arrange for medical attention for the injured and for the elimination of unsafe conditions or unsafe actions, or both.

8.2 Safety and protection measures

8.2.1

The following specific safety and protection measures shall be provided for in accordance with the OHS Act, 1993:

• – first-aid treatment;
• – medical assistance;
• – emergency treatment;
• – prevention of inhalation of fumes; 43
• – protective clothing;
• – protective footwear;
• – protective equipment;
• – breathing apparatus;
• – safety belts; and
• – safety goggles or eye shields.

8.2.2 Contact with petroleum products

Contact with petroleum products and the associated dangers require that the following points be attended to:

• – prevention and treatment of contamination;
• – prevention and treatment of occupational diseases;
• – prevention of contamination by leaded petrol;
• – provision of safe access to confined spaces;
• – correct handling of materials and packages by hand;
• – accident reports;
• – good housekeeping;
• – welfare facilities; and
• – material safety data sheet.

9 Maintenance of and extensions to depots

9.1 Risk assessment procedure

9.1.1 General

Before any extensions can be made to an existing depot, a full risk analysis in terms of the legislation of the Major Hazard Installation Regulations (see the OHS Act, 1993) shall be made. Any maintenance of or extensions or repair work to a petroleum depot shall follow but not be limited to the following procedure:

1. lay down clearly defined responsibilities;
2. adopt specific and explicit rules and regulations;
3. ensure that instructions and orders given are simple and clear; and
4. ensure that the cathodic protection system is turned off before the start of any work on pipelines, pumps, valves, etc.

44

The utmost vigilance is required to ensure that deviation from regulations is avoided, particularly when personnel are engaged in work in hazardous areas or when the staff of an outside contractor are employed.

During such operations, tanks and plants that have been used for a class II petroleum product shall be treated as if they had been used for a class I product.

Tanks and items of plant that have been used for a class III petroleum product present a reduced risk, and do not require the same precautions as in the case of a class I or a class II petroleum product. Nevertheless, care is still necessary, and in the case of repairs and maintenance proceed with caution, bearing the proximity of any class I or class II plant in mind.

9.1.2 Hot work

When any hot work is to be carried out in a hazardous area that contains a petroleum product, a high degree of control and supervision shall be maintained. A permit that authorizes the work shall be issued in writing in accordance with 9.8. (See also annex C.)

NOTE All petroleum products become flammable when heated to their flash points.

9.2 Repairs and alterations

9.2.1 General

Repairs or alterations shall not be permitted on any plant or equipment while such plant or equipment is in use (for example, when a tank or vessel is being loaded or unloaded). The local fire-fighting services shall be informed when water is not available or when any work is being carried out on major fire-fighting installations.

9.2.2 Equipment

When repairs or alterations necessitate the dismantling of essential items of plant such as valves, pumps and pipelines, a specific notice shall be issued to all concerned. The work shall not be started until acknowledgement of the notification has been received.

9.2.3 Tanks and vessels

No hot or other hazardous work shall be started inside a tank or vessel in which a class I, a class II, or a class III petroleum product has been stored until such time as the tank or vessel has been inspected, a gas-free certificate has been issued (see 9.8), all pipelines have been disconnected and all relevant authorities have been notified.

No person shall be allowed to enter a tank or vessel that has not been declared gas-free unless such person is equipped with suitable breathing apparatus. An observer shall be stationed at the manhole whenever work is to be done on such tank or vessel. Observers shall be instructed to watch the workers carefully and to take immediate action or summon assistance if any person(s) collapses(collapse) inside the tank or vessel.

Observers and other rescue personnel shall be equipped with the proper safety gear so that they themselves will not succumb during rescue operations. Special attention shall be given to the manholes, scaffolding (see SANS 10085-1) and rigging, to ensure safe entry and exit. When tank cleaning, repairs or alterations are involved, the special instructions applicable to this type of work shall be rigorously observed. (See also 9.9 and annex C.)

Amdt 2

9.2.4 Pipelines, pumps and valves

In the event of a broken connection, no reliance shall be placed on closed valves. Complete drainage shall be effected and openings shall be closed properly by means of blank flanges or line

45

blinds. Any spillage of product shall be collected and disposed of in an acceptable way. When continuity in a pipeline is broken, the work area shall be bridged with a heavy electrical jumper cable to reduce the risk of sparks from stray or induced currents.

9.2.5 Electrical equipment

An accredited person shall certify that the electrical equipment has been isolated and locked out safely before any repair, adjustment or test is commenced. Warning notices (symbolic signs) shall be hung onto or affixed to main switches or circuit-breakers, to prevent accidental switching-on while repairs are in progress. After repairs have been completed, an accredited person shall certify that the apparatus is in order, both mechanically and electrically, before it is brought back into use. (See SANS 10089-2.)

9.2.6 Lock-out requirements

Only authorized personnel shall be able to lock out equipment. All lock-out systems shall comply with the requirements of the OHS Act, 1993.

9.2.7 Records

For certain types of plant and equipment such as pressure vessels, cranes, and electrical apparatus, an adequate system of keeping permanent records shall be maintained for all repairs, inspections and tests, in compliance with the OHS Act, 1993.

9.3 Personnel

9.3.1 Safety

All staff engaged in operational maintenance duties shall be fully acquainted with the requirements of the safety regulations in terms of the OHS Act, 1993.

9.3.2 Supervision

Maintenance and inspection work shall be planned and supervised by responsible members of staff, who shall ensure that all relevant precautions are observed.

9.3.3 Use of casual and contractors’ labour

When casual and contractors’ labourers are employed, they shall be familiarized with all the relevant precautions adopted by the depot. The necessary precautions to be taken shall have been thoroughly explained to them before any work is commenced. (See section 13 (Duty to inform) of the OHS Act, 1993.)

When such labourers are employed in or adjacent to a hazardous area, strict supervision shall be arranged to ensure that all relevant precautions are observed.

9.4 Plant

When mobile plant is temporarily stationed in a hazardous area for maintenance, repair or other purposes, care shall be taken to ensure that the plant is of such construction that it is not likely to cause a fire by the emission of sparks or flames, or by any other source of ignition.

No plant belonging to a contractor shall be used on the premises without the written permission of the depot manager or his authorized representative.

46

9.5 Access to site

The use of vehicles and plant on the site, particularly in hazardous areas, shall be defined and controlled and the routes to and from such areas shall be clearly indicated.

9.6 Temporary fencing

Personnel or contractors shall be prevented from gaining unauthorized access to a hazardous area and, when necessary, temporary fencing, portable barriers or screens shall be provided.

9.7 Notices

Warning notices shall be prominently displayed where necessary (see also 7.15 and 9.2.5).

9.8 Permits

9.8.1 General

To ensure safety, construction and repair work shall only be performed in a depot if written permission has been granted by the manager or his authorized representative. All permits issued shall be specific with regard to their purpose. A permit can be cancelled at any time if conditions are considered to have become unsafe. (See examples in annex C.)

9.8.2 General or cold-work permits

General or cold-work permits shall be issued by the designated person to allow any work within the depot that does not involve hot work (which could cause ignition) or entry into confined spaces. (See examples in annex C.)

9.8.3 Gas-free certificates

Gas-free certificates shall be issued by a person who has received formal training in the properties of flammable liquids and in the operation, calibration, maintenance and use of the type and model of gas testing device employed to determine the presence of hazardous vapours in the workplace, and who has been vested (in writing, by the employer) with authority to issue gas-free certificates (see 9.10.2). (See examples in annex C.)

9.8.4 Hot-work permits

Hot-work permits shall be required wherever hot work is to be done in an area in which flammable vapours might exist. A hot-work permit is issued on the condition that a normally safe area remains safe for the duration of the work, or that an area which is normally hazardous be converted into a temporary safe area for the duration of the work. Hot-work permits shall be issued by a person who has been vested (in writing, by the employer) with authority to issue hot-work permits. (See examples in annex C.)

9.8.5 Confined-space entry permits

Confined-space entry permits shall be required whenever it is necessary to enter a confined space that contains, or has contained, a flammable or toxic atmosphere and from which easy and ready escape is hampered. A gas-free certificate shall also be required. Confined-space entry permits shall be issued by a person who has been vested (in writing, by the employer) with authority to issue confined-space entry permits. (See examples in annex C.)

The designated person may subdelegate the extension of the period of validity of permits that he has issued to a responsible person, provided that conditions do not change in a way that would constitute an increased hazard.

47

9.9 Safety

9.9.1 Safety conditions

It is difficult to recommend hard and fast safety rules that should be observed during maintenance work in operating plants, and the recommendations given in this part of SANS 10089 might have to be modified or adapted. Pay due regard to the petroleum operations being carried out at the time, and to the weather, humidity, wind direction, topographical features of the site, and the availability of assistance from outside should emergencies arise during the work.

9.9.2 Safety distances

Unless it is unavoidable, no hot work, rivetting or welding shall be permitted within 15 m of a tank or vessel that contains class I or class II petroleum products, or within 6 m of one that contains class III petroleum products.

These distances are minimum distances that might have to be increased because of local conditions or specific circumstances. Bear in mind also that an area that has been classed as safe could become hazardous owing to a change in wind direction. In addition to professional judgement, use a gas detector to assess the conditions in each situation.

Ensure that any working tank of which any part is within these distances, is emptied, and that a gas-free certificate is issued by a qualified person. Where these distances cannot be adhered to, a qualified person shall supervise the work (throughout its duration) and such person shall strictly enforce the necessary precautions.

9.9.3 Fire danger

In hazardous areas, special precautions shall be taken, such as the temporary resiting or supplementing of fire equipment to cover an emergency or, when it is deemed expedient, the provision of fire-watchers to detect incipient fire and to bring first-aid and fire-fighting equipment into immediate use. Brief but explicit instructions shall be given to any contractor regarding the action to be taken in the event of a fire. (See also clause 6.)

9.10 Gas-freeing of tanks

NOTE If a plant falls (because of its power rating or for any other reason) under the jurisdiction of the Chief Inspector appointed in terms of the OHS Act, 1993, the Chief Inspector is the overriding authority, and recommendations given in this clause are additional to and subject to compliance with the requirements issued by the Chief Inspector.

9.10.1 General

A tank that has contained a volatile hydrocarbon might have to be gas-freed before the tank can be cleaned or repaired. (This is done to protect persons from the toxic and asphyxial effects of the hydrocarbon, and to make the repair operation safe from the hazard of fire.)

When a combustible-gas indicator (gas detector) has been used to confirm freedom from flammable vapours, the atmosphere within the tank could still be deficient in oxygen or could contain toxic components. In all cases of doubt, appropriate chemical tests shall be carried out. (For more detailed information regarding the cleaning of leaded gasoline tanks and the disposal of sludge, refer to OCTEL directive Lead alkyl antiknock compounds (see 2.2).)

9.10.2 Gas-free certificate

A gas-free certificate is required when:

1. any hot work is to be done in a restricted area; or 48
2. when entry into any confined space is required, i.e. in addition to the confined-space entry permit.

In the latter case, special attention shall be given to the oxygen content, as required by the OHS Act, 1993.

9.10.3 Vapour travel

Hydrocarbon vapours are denser than air and, although they can be dispersed easily and safely by a light breeze, a dangerous concentration can travel a considerable distance in a still atmosphere. The large volume of an air-and-hydrocarbon-vapour mixture that could be released during a gas-freeing operation can travel beyond the limits of the usual safety distances, and it is therefore recommended that all possible sources of ignition in the entire area be eliminated at all times during gas-freeing. Persons shall be kept clear of the bunded area and the down-wind area as far as possible, especially where gas and air from the tank cannot be discharged at a high level.

9.10.4 Lower explosive limit (LEL) and upper explosive limit (UEL)

Mixtures that contain about 1 % to 10 % (by volume) of petroleum vapours in air are flammable. If there is less than 1 % or more than 10 % of vapour, the mixture will be too lean or too rich to burn. The limiting values of 1 % and 10 % are known as the lower explosive limit (LEL), and the upper explosive limit (UEL) respectively.

NOTE The approximate relationship between temperature, Reid vapour pressure, and explosive limits of petroleum products is given in figure 2.

9.10.5 Measurement of vapour concentration

The quantity of vapour in an air-and-vapour mixture can be measured by means of a gas detector.

NOTE Gas detector scales are graduated from 0 to 100, their graduation being based on the lower limit of flammability of 1 %. A reading of 50 indicates 50 % of the lower limit of flammability (i.e. the mixture contains 0,5 % of vapour), and a reading of 20 on that scale indicates 0,2 % of vapour.

The instrument used for recording the concentration of this vapour shall be of approved design and shall be regularly calibrated and tested for accuracy.

9.10.6 Permissible petroleum vapour concentration

Vapour concentrations and the corresponding safeness of working conditions are given in table 6.

49

Figure 2 — Approximate relationship between temperature, Reid vapour pressure and explosive limits of petroleum products

50

9.10.7 Methods of gas-freeing and their applicability

The methods of gas-freeing in 9.10.7.1 to 9.10.7.4 can be used, either singly or in combination.

9.10.7.1 Ventilation by forced or natural draught

This method is recommended in the case of storage tanks where the use of steam or water is impracticable or undesirable.

9.10.7.2 Flooding with water

Gas-freeing by flooding with water has the disadvantage that it cannot be relied on to remove all petroleum vapour, liquid, and solid residues. Furthermore, before the method is adopted, the tank and its foundations have to be verified as being capable of sustaining the mass of the vessel filled with water. To avoid the build-up of a static charge when this method is used, the flooding water shall be introduced at the base of a tank and, if a hose pipe is used, the flow rate shall be kept low and the nozzle shall be electrically earthed.

9.10.7.3 Steaming

This method can be used in the case of small storage tanks and medium-sized insulated tanks. In the case of certain products, complete removal by steam is not always possible, and a residue might remain that could be ignited during welding. Only low-pressure steam shall be used, and steam hoses shall be electrically bonded to the tank shell.

NOTE Steam degassing can present the danger of tank implosion should rapid steam condensation occur.

9.10.7.4 Purging by inert gas or flue gas

This method can be used where it is impossible to displace flammable gases or liquids with steam, water or air because of their effect on the contents of the tank. This method involves a danger that, when air later displaces the inert gas, any pyrophoric deposits that are present could burst into flame. In addition, the tank atmosphere will not be fit to breathe after purging and the inert gas will have to be swept out with air and a test for sufficiency of oxygen will have to be carried out before anyone can enter without breathing apparatus.

9.10.8 Procedure for gas-freeing

The procedure for the gas-freeing of tanks varies according to the type of tank.

Gas-freeing does not ensure the safety of persons who enter tanks that have contained leaded petrol unless appropriate protective clothing is worn.

Conduct gas-freeing operations only under the direct supervision of a designated person, and use the appropriate procedure described in 9.10.8.1 to 9.10.8.4.

9.10.8.1 Above-ground fixed-roof vertical storage tanks (conventional types)

Carry out the following procedure:

1. Empty the tank of product.
2. Disconnect all pipelines at the tank valves, blank off open ends of pipes and, if there is any possibility that tubular housings and conduits connected to the tank for gauging or other instrumentation purposes might contain product, disconnect them.
3. Open all tank valves that lead to the atmosphere and all manhole covers in the roof of the tank. 51
4. Open shell manhole covers. Do this carefully and, by opening the covers only partially at first, prevent the escape of an excessive initial volume of gas.
5. Thoroughly ventilate the tank. Ventilation is normally assisted by the use of wind-sails at roof manholes, and by the use of a fan or an eductor if compressed air, steam or electric power is available.

As petroleum vapours are denser than air, it is preferable that fresh air be drawn into the tank at a high level and that the effluent vapour be extracted, via flexible trunking from a top manhole, at a low level (about 2 m above the tank floor).

If possible, do not expel air from a low level (for example from a manhole at the bottom or side), since vapour will concentrate in the bund area and create a hazard.

Continue ventilation until gas detector tests show either a safe concentration of, or freedom from petroleum vapour. A tank can be considered free from gas when a series of gas detector tests are carried out at 5 min intervals over a 30 min period at several places in the tank and all gas detector readings are below 4. Before anyone starts working in the tank, provide maximum dilution of the atmosphere in the working area by moving the air inlet to a low level. To prevent any build-up of flammable vapour when sludge is disturbed, continuous ventilation is necessary throughout a tank-cleaning operation. Discontinue forced ventilation and tank-cleaning during an electrical storm.

Use a gas detector, as and when required, to check that tanks that have been freed from gas remain gas free throughout the period during which maintenance work is being carried out.

9.10.8.2 Floating-roof tanks

Follow the same general procedure as detailed in 9.10.8.1. Facilitate entry by supporting the floating roof by its extended vertical columns (or other means), and open roof fittings, manhole covers, and dip hatches to facilitate ventilation. The use of wind-sails on this type of tank is often not practicable, but ventilation can be accelerated mechanically by the use of wind-scoops made of suitable material and located in the side manholes, or by the use of fans or eductors. When testing for vapour concentration, include the space in the tank that is above the roof and inside the pontoons. Open and ventilate pontoons and double decks, and use a gas detector to check each such space individually.

Ensure that water-drainage systems are clear of product, by opening and flushing them.

9.10.8.3 Above-ground horizontal tanks

After draining the horizontal tank as completely as possible of its contents, remove the manhole covers and use water as a flushing medium. Before flushing the tank, ensure that all pipelines are disconnected and blanked off and all apertures fully opened. Ventilation can be accelerated by means of a wind-sail or by mechanical means.

9.10.8.4 Below-ground and mounded tanks

Follow the same general procedure as in the case of fixed-roof tanks (see 9.10.8.1), but remember that it is essential to ventilate access chambers, valve chambers, and tunnels ancillary to the tank as well, and to include these places in the testing procedure.

9.11 Cleaning of tanks

9.11.1 Tanks used for the storage of leaded class I petroleum product

The cleaning of these tanks is a hazardous operation owing to the presence of toxic organic lead derivatives in the atmosphere and in the sludge and scale from the inside walls and roofs of the

52

tanks. The tanks therefore require special treatment in the cleaning process, and the instructions issued by the manufacturer of the lead compound regarding the procedure and the safety measures to be adopted have to be observed rigidly. Tanks that have, at any time, contained a leaded product shall carry, near each manhole, a permanent warning notice to this effect.

9.11.2 Tanks used for the storage of unleaded class I and class II petroleum product

9.11.2.1 Cleaning under other than gas-free conditions

When the cleaning of a tank involves the entry of persons and the tank cannot be completely gas-freed and maintained in that condition throughout the entire operation, the following precautions shall be observed:

1. Ensure that cleaning is carried out under the direct supervision of a qualified person.
2. Remove as much highly flammable liquid and sludge as possible from the tank through a closed pumping system, then drain out the remaining contents of the tank via the main and drain lines, and disconnect these and any other lines that are connected to the tank. Blank off all tank valves and disconnect pipelines. Reduce hand bailing and mopping-out to a minimum.
3. Keep the tank as well ventilated as possible during cleaning operations.
4. All persons who enter the tank shall be equipped with safety equipment in accordance with the requirements of the OHS Act, 1993. While work is in progress, ensure constant supervision by a qualified person stationed outside the tank and equipped with suitable breathing apparatus that enables him to enter immediately, should the need arise. A safety line shall also be immediately available.
5. The period for which persons may be allowed to remain in the tank continuously will vary with site conditions, but it is recommended that this period in no case exceeds 1 h 30 min and that there be a break of at least 30 min before such persons return to the tank.
6. Ensure that all clothing, any part of which has become saturated, is removed immediately and washed and dried before being worn again. (See also 9.9.1.)
7. Examine, test, clean, and sterilize breathing apparatus on each occasion before use.
8. Ensure that the breathing apparatus correctly fits the person who is to wear it, and is maintained in sound working order.
9. During cleaning, use compressed-air-operated lights and equipment inside the tank. Alternatively, battery-operated or mains-operated equipment and lighting may be used, provided that they are of flameproof, intrinsically safe, or approved construction. Connect electrical equipment to the power supply by means of a flexible lead of an approved type (see SANS 10089-2). Pass cables for lighting through the roof manhole. Do not use side manholes for this purpose, and do not allow the mass of suspended lighting to be carried by its cable.
10. Ensure that the accumulation of sludge and corrosion scale from the cleaning operation is handled in a wet state only, both in the tank and after removal. Disposal of this sludge and scale should be carried out by burning or by chemical treatment.
11. In the case of hard deposits that necessitate the use of chipping tools, ensure that the surface being chipped is kept thoroughly wetted during the operation.
12. Ensure that water hoses, fire extinguishers and sand are available in the immediate vicinity throughout tank-cleaning operations.

53

9.11.2.2 Cleaning under gas-free conditions

In the case of a tank that is free from gas and can be maintained in that condition throughout the entire operation, only the precautions given in 9.11.2.1(a), 9.11.2.1(f), and 9.11.2.1(j) have to be observed, while the workers should still be provided with suitable clothing (see the OHS Act, 1993).

Tanks that are being cleaned under gas-free conditions may be illuminated as in 9.11.2.1 (i), or by low-voltage a.c. (below 50 V) portable lighting equipment. The supply cable to the flameproof transformers for low-voltage lighting equipment shall always be so supported that the cable is held clear of the ground, and a transformer shall never be taken inside a tank.

9.11.2.3 Cleaning of vehicle and other small tanks

Rail tank vehicles, road tank vehicles and storage tanks of limited size can be conveniently cleaned by equipment operated from outside the tank and in these cases only the precautions given in 9.11.2.1(a) and 9.11.2.1(j) have to be observed.

All effluent and excess water shall be treated before it is passed into the drainage systems. (See also 4.9.5.)

9.11.3 Tanks used for the storage of class III petroleum product

Provided that tanks that previously contained a class III product are ventilated adequately during cleaning operations and that persons working in them wear suitable protective clothing, no special precautions are necessary.

10 Transportation of petroleum products (other than LPG) by road and by rail

NOTE Rail transportation falls within the jurisdiction of Spoornet. In the case of road transportation, compliance with the relevant provisions of the Road Traffic Act and with the requirements of the local licence authority is necessary.

All bulk road and rail vehicles for petroleum products shall be constructed in compliance with an approved standard and shall conform to sound engineering design. (See also SANS 1518, SANS 10228, SANS 10229-1, SANS 10231, SANS 10232-1, SANS 10233 and SANS 10263) The regulations for the transportation of hazardous goods and the local by-laws shall be adhered to.

Amdt 1; amdt 2

11 Pollution control

The design and operation of the installation shall be such that the storage and handling facilities will not cause contravention of the National Water Act, 1998. In particular, all reasonable steps shall be taken to prevent pollution of both underground water and surface water.

All waste shall be disposed of in an approved manner. (See also 4.9.)

54

Annex A
Determination of water requirements for the highest fire risk area

(informative)

A.1 Introduction

Water requirements for fire-fighting purposes should be determined for the highest fire risk with the largest fire surface area in a depot.

The fire risks in a depot should be determined by means of a risk assessment.

A.2 References

The definitions in A.3 and research for this annex have been collected from the various publications as listed below:

AIChE (CCPS), Guidelines for chemical process quantitive risk analysis.

Amdt 2

AIChE (CCPS), Guidelines for hazard evaluation procedures.

Amdt 2

API RP 2030, Application of fixed water spray systems for fire protection in the petroleum and petrochemical industries.

Amdt 2

NFPA 11, Low-, medium-, and high-expansion foam systems.

NFPA 15, Water spray fixed systems for fire protection.

UNEP IE/PAC Technical Report No. 12, Hazard identification and evaluation in a local community.

A.3 Definitions

For the purpose of this annex, the following definitions apply.

A.3.1
accident

an unplanned event or sequence of events that results in undesirable consequences. An incident with specific safety consequences or impacts

A.3.2
credible event

an event that has a degree of probability (likelihood) of occurring, or for which reasonably practical mitigating actions can be taken by the owner of the depot to minimize the consequences (or both)

A.3.3
consequence

the direct, undesirable result of an accident, usually involving a fire, an explosion, or the release of toxic material. Consequences may be expressed as either quantitative or qualitative estimates of the effects of an accident in terms of factors such as health impact, economic loss, and environmental damage

NOTE Severity is very often used as a synonym or to express the degree of consequence.

55

A.3.4
event

an occurrence related to equipment performance or human action exernal to the system that causes a system upset. An event is either the cause of or a contributor to an incident or accident, or is a response to the event that initiated an accident. Fire, explosion, and toxic release are typical events

A.3.5
external event

any event that occurs external to the system considered

NOTE Examples are: lightning, extremely unusual weather conditions, earthquake, landslide, flooding, actions of third parties or failure of their equipment outside of the property of the depot but impacting on the depot.

A.3.6
hazard

a chemical or physical condition that has the potential to cause damage to people, property, or the environment

NOTE A common synonym is “risk source”.

A.3.7
hazard evaluation/analysis

the analysis of the significance of hazardous situations, or other processes or activity. It uses qualitative techniques to pinpoint weaknesses in the design and operation of facilities that could lead to accidents

A.3.8
hazard identification

the pinpointing of material, system, process, and plant characteristics that can produce undesirable consequences through the occurrence of an accident

A.3.9
incident

the loss of hazardous material from containment or the release of hazardous forms of energy (for example, in a “near miss")

A.3.10
incredible event

an event that is extremely improbable (with, for example, a likelihood of less than 1 in 1 000), or for which “reasonably practical” measures to minimize the consequences are beyond the capabilities of the owner of the depot, or both

A.3.11
likelihood

a measure of the probability or expected frequency of an event’s occurrence

A.3.12
probability

an expected chance for certain events to happen within a certain period of time

A.3.13
risk

the combination of the expected probability of an event and the consequence of that event. It is a measure of economic loss or human injury in terms of both incident likelihood and the magnitude of loss or injury. (Risk = Severity × Probability.)

56

A.3.14
risk analysis

the development of a quantitative estimate of risk based on engineering evaluation and mathematical techniques for combining estimates of incident consequences and frequencies. It is the systematic identification and evaluation of risk objects and hazards

A.3.15
risk assessment

the process by which the results of a risk analysis (i.e. risk estimates) are used to make decisions, either through relative ranking of risk reduction strategies or through comparison with risk targets

A.3.16
risk estimation

the process of combining the estimated consequences and likelihood of all incident outcomes from all selected incidents to provide a measure of risk

A.3.17
risk object

any object that could institute a risk within the perimeter of a bulk storage depot (for example, tanks, tank bund, loading racks, rail sidings, warehouses, workshops, etc.)

A.3.18
risk targets

objective-based risk criteria established as goals or guidelines for performance

A.3.19
worst case

the possible event with the worst consequences. There are three types of “worst case":

1. the consequences are so limited that the risk is unimportant, whatever the probability of the event;
2. the consequences are so serious that the probability of the event must be very small (low) if there is to be a tolerable level of risk; and
3. the worst possible consequences are irrelevant since the probability is so low that the risk is negligible.

(See also UNEP IE/PAC Technical Report No. 12.)

A.4 Hazard evaluation and risk assessment

There are numerous hazard evaluation techniques. Each technique has a specific purpose, benefits, costs and limitations. Some are qualitative techniques whilst others are quantitative methods, and a few are a combination of qualitative and quantitative methods.

A.4.1

The most common hazard evaluation techniques are:

1. Safety review
2. Checklist analysis
3. Relative risk ranking
4. Preliminary hazard analysis (PHA)
5. What-if analysis 57
6. Hazard and operability analysis (HAZOPS)
7. Failure modes and effects analysis
8. Event tree analysis
9. Fault tree analysis
10. Cause-consequence analysis k) What-if/checklist analysis l) Human reliability analysis

A.4.2

The most suitable and practicable techniques for a petroleum bulk depot are any of the following:

1. Safety review
2. Checklist analysis
3. Relative risk ranking
4. PHA or HAZOPS
5. What-if analysis

The technique(s) used for the hazard evaluation shall be at the discretion of the responsible engineer.

NOTE It has been found that the application of simple qualitative assessment techniques for depot assessments give results that are very similar to those of the more complicated in-depth techniques.

A.5 Consequence analysis

In addition to the hazard evaluation listed in A.4, there is another method, called quantitive consequence analysis (QCA). In most cases it is sufficient to estimate the order of magnitude of the consequences. It is not always necessary to estimate in great detail. In a few cases it may be necessary to conduct QCA for a depot, for example when modelling the spread of gases (toxic or LPG) and their effects.

A.6 Example of a risk analysis

NOTE This example only gives the key features of a full analysis.

The following details deal with PHA, one of the techniques listed in A.4, to serve as a typical illustration of a major risk analysis approach. The primary components of a PHA are:

6. hazard identification, which may be extended to hazard evaluation and, still further, to a quantitative risk analysis depending on the depth of analysis required to obtain more information;
7. risk index evaluation; and
8. risk mitigation.

In A.6.1, the specific example of a PHA for a fuel depot is outlined. 58

A.6.1 Hazard identification, hazard evaluation and quantitative risk assessment

A.6.1.1

List the various hazardous events.

A.6.1.2

Follow each event through to its conclusion (without any controls applied) and record the consequences.

A.6.1.3

Identify and record existing active and passive controls which would limit the probability of the event or the severity of the consequences.

NOTE

1. Examples of passive controls are: preventative safety measures such as engineering design and layout, equipment specifications, control of ignition sources, standard safe operating procedures, training of personnel in procedures, selection of fire-resistant materials, specialized electrical equipment, inspection and maintenance of facility.
2. Examples of active controls are: emergency shut-off equipment, emergency shut-off and response procedures and training, provision of fire-fighting equipment and checks on the reliability of fire-fighting equipment.

A.6.1.4

Review the critical factors such as operating procedures, training, fire protection systems and emergency shutdown devices which could influence the likelihood of an event occurring, or the severity of the incident. The information obtained from such a review is then considered when determining a risk index value for the event.

A.6.2 Risk matrix

A.6.2.1

Once the definition and ranking of likelihood and consequence are determined and tabulated, a corresponding 5 × 5 matrix can be constructed (see the example in figure A.1).

The risk index (RI) for any event is calculated as the product of its likelihood and its consequence value in the risk matrix.

A.6.2.2

The first steps in drawing up a risk matrix are to define the ranking of likelihood and the ranking of consequence (or severity) of events.

Both the likelihood and consequence (or severity) of various events are given a ranking value on a subjective scale, as in the example of a five-point ranking given in table A.1.

A.6.2.3

The standard definitions of likelihood and severity may be modified to accommodate local factors relevant to the installation being evaluated and 3 × 3 or 4 × 4 risk matrices may be used. Examples that illustrate the use of likelihood and consequence definitions and ranking for a particular case study are given in tables A.2 and A.3.

59

Figure A.1 — Typical (5 × 5) risk matrix

60

61

A.6.2.4

The severity values used for a risk assessment study should be based on factors that are mutually agreed upon with the respective company management before use. Some critical aspects in the above example are:

1. The tank spacing between the tank on fire and the adjacent threatened tanks. If the tank spacing is less than one tank diameter of the tank on fire, it can be assumed that the adjacent tank would be exposed to excessive radiant heat loads, regardless of wind direction. If one adjacent tank is exposed, a severity value of 4 is assigned. If two adjacent tanks could simultaneously be exposed to the fire, a severity value of 5 is assigned.
2. The criticality of the tank on fire is a function of the product stored, and whether alternate storage arrangements could be made if a tank fire occurred. If there are difficulties regarding alternate storage arrangements for a strategically important product, a minimum severity value of 4 is assigned regardless of the number of additional tanks exposed to the fire.

62

A.6.3 Risk mitigation

Risk mitigation involves the implementation of measures that reduce the risk index (RI) to an acceptable value. Such measures could be either passive or active controls (see A.6.1.4) or both. If the RI for an event can be reduced to an acceptable level by passive control alone, and it is cost effective, then there is obviously no justification for additional fire protection systems.

The example in A.6.1 and A.6.2 is only one typical example of one of the risk assessment techniques.

NOTE Generally, the oil industry worldwide tends to consider only those recommendations that would be necessary to reduce the risk index for an event to below 9. Additional mitigation measures could be taken to reduce the RI further, but might not be cost-justified. RIs of 8 and below are considered acceptable risks which the oil industry is prepared to take.

A.7 Water requirements for some typical events

Water requirements in the management of fire effects (see note) are expressed as total flow in litres per minute and calculated pressure.

NOTE The management of fire effects is the fire-fighting strategy which involves any one or a combination of the following, often in the priority order given:

1. safeguard exposures against fire;
2. control or contain fire; and
3. extinguish fire.

The water is applied together with foaming agents for extinguishing and, if required, for control of a petroleum fire. (Foaming agents are not necessarily required for safeguarding exposures and for control or isolation purposes.) Some typical events which are generally included in risk assessments are given in A.7.1 to A.7.4. The results of a risk assessment for a depot will identify the highest risk with fire area that has the largest horizontal surface area.

A.7.1 Tank fire in the tank with the largest fire surface area

A.7.1.1 Calculation of water requirement for foam application to the tank on fire

The determination of water requirements is dealt with in the latest edition of NFPA 11 or in the information service of the supplier of foam and equipment. The following shall be taken into account when determining water requirements:

1. the tank dimensions;
2. the liquid surface area, in square metres;
3. the type of product;
4. the type of foam specified for the product;
5. the method of application;
6. the foam application rate for the method specified and for the product, in litres per minute per square metre of the liquid surface area; 63
7. the flow specification of foam appliances, in litres per minute, and the inlet pressure, in kilopascals;
8. the number of foam appliances required; and
9. the specified application time, in minutes.

NOTE For the calculation of the minimum pressure see 7.8.8.

A.7.1.2 Other water requirements

A.7.1.2.1

The determination of cooling water requirements (as in (a) to (c)) is dealt with in the latest editions of NFPA 15 and oil industry specific API Publication 2030.

1. cooling water for the tank on fire: at an application of 4,1 litres/minute/m² of protected surface. The application of cooling water to a tank is of potential benefit only for the exposed portions of the roof and those portions of the shell that are not in contact with the liquid (product) in the tank. If a water spray is used, typically only the upper 3,7 to 7,4 metres of the shell is sprayed; up to 3,7 metres rundown is allowed on inclined and vertical surfaces. (See API Publication 2030.)

   This amounts to 15,1 to 30,3 litres/min/linear metre circumference of the tank for a fixed cooling system; or 30,3 to 62 litres/min/linear metre for portable equipment.

2. cooling water for any adjacent tanks: as determined during the risk assessment, in general, if an adjacent tank is within one tank diameter of the tank on fire. This cooling water need only be applied to the exposed quadrant to half of the adjacent tank(s), at the application rate given in (a).

   Since the exact location of the exposing fire or the amount of liquid in the exposed tank may not be known before the fire occurs, total protection would require that the entire tank be sprayed. However, water sprayed on surfaces that are not exposed to fire is wasted and takes resources from other fire suppression efforts. Application of cooling water by hose streams and monitors is generally a more efficient use of available water.

3. Once foam application to the tank on fire has commenced, cooling water for threatened tanks might not be required. The maximum water flow required for the tank on fire or the adjacent threatened tanks and facilities should be available.

A.7.1.2.2 Other water requirements to consider

Take into account any water required for the protection of fire-fighters and to be used for isolation of adjacent tanks if deemed necessary, and determined by the number of hose streams required at 250 to 450 litres per minute per hose.

A.7.2 Bund spill fire as a result of the largest tank failure

A.7.2.1 Calculation of water requirements for foam applications to bund spill fire

The largest tank is assumed to be full when it ruptures, spilling its contents into the bund. Refer to the latest edition of NFPA 11 and to the supplier(s) of foam and equipment for foam, equipment and water requirements. The following have to be taken into consideration:

1. the total spill containment surface area, in square metres;
2. the type of product (hydrocarbon or polar solvent); 64
3. the method of foam application;
4. the foam type specified for the product;
5. the application rate for the foam, in litres per minute per square metre;
6. the minimum application time, in minutes; and
7. the minimum operating pressure required by the foam appliances being used.

A.7.2.2 Allowances

An allowance should be made for the application of foam into the failed tank if it has not totally collapsed. Calculate the water flow for foam application as in A.7.1.1.

A.7.2.3 Remote bunding

If remote bunding was provided as additional containment for the spill, then follow the same calculation as in A.7.2.1. Generally, the principle of remote bunding is to contain a spill in a safe location where there is no threat to adjacent facilities. If so, foam application need only commence in the remote bund once the fire in the main bund has been extinguished.

A.7.2.4 Water requirements

The required total water flow is equal to the requirement as determined in A7.2.1 or A.7.2.3, whichever is the greater, based on the principle of fighting one bund fire at a time.

A.7.2.5 Water flow availability

The total water flow shall be available from the fire main for at least 1 h. The total flow as given in A.7.2.4 should be guaranteed for the minimum application time for the type of application and for the type of product as defined in A.7.2, based on the principle of fighting the ground and bund fire first before fighting the tank fire.

A.7.3 Loading rack operational spill fire

The considerations in A.7.3.1 to A.7.3.5 are applicable to both bulk truck loading racks and rail sidings.

A.7.3.1

Distinguish clearly between the various types of event.

A.7.3.1.1

One event is the release of the total contents of a truck or tank car into the containment area and oil/water separator(s) or remote impounding area if provided, or both.

A.7.3.1.2

Another event could be the release of only a quantity of product which depends on the effectiveness of the emergency shut-off response.

NOTE The maximum allowable emergency shut-off response time should not be more than 2 minutes. The maximum anticipated spill in litres is then equal to the product of this response time (in minutes) and the spill release rate (in litres per minute).

A.7.3.1.3

Yet another event could be an explosion due to switch loading and the release of the contents of the tanker.

NOTE A bulk truck has a far greater likelihood of releasing the contents of at least one compartment (or more) than a tank car, because a bulk truck is constructed of aluminium and is loaded with closed domes for

65

bottom loading, and emergency venting is generally not provided for. Tank cars are constructed of steel and loaded with open domes, thus providing adequate emergency venting. All of this should be considered in the risk assessment.

A.7.3.1.4

Yet another event is the derailment of a tank car which could result in the total contents of the tank car being released as in A.7.3.1.1, or a portion of the tank car contents being released.

A.7.3.2

Design for the highest risk, as determined by a risk assessment of the various events.

A.7.3.3

Determine the spill fire area for the highest risk.

A.7.3.4

Refer to the latest edition of NFPA 11 and to suppliers of the foam and equipment to determine foam water requirements.

Calculate the foam water flow required in litres per minute.

The calculation of the water requirement should take into account the following:

1. the spill fire surface area at the loading rack or siding, in square metres (determined from the volume of product released and the topography of the containment area);
2. the type of product released (assume worst case type of product);
3. the method of foam application (foam/water sprinklers, fixed monitors, or portable equipment);
4. the type of foam;
5. the foam application rate in litres per minute per square metre; and
6. the minimum foam application time, in minute.

Calculate the foam water required in litres per minute.

A.7.3.5

Ensure that cooling water for pressure fires (minimum 2 hoses, streams of 125 to 250 litres per minute) is provided if no fixed foam/water sprinklers or fixed monitors exist or only portable foam equipment is provided. Generally, pressure fires in depots would be extinguished by closing remote valves and switching off pumps, and a pressure fire on a tanker could be extinguished by dry chemical powder extinguisher. Additional water requirements for fire-fighters might be required for isolation if remote isolation is not provided (determine the number of hose, streams of 250 to 450 litres per minute). Hence calculate the total water flow requirements.

A.7.3.6

The total water flow requirements should be available for at least 1 h.

A.7.4 Operational spill fire in the bund due to a tank overfill

A.7.4.1

Refer to NFPA 11 and the suppliers of foam and equipment to determine the total water flow requirements. The calculation of the water requirement should take into account the following:

1. the anticipated spill volume (the product of the flow rate and the response time for emergency shut-off), in litres;
2. the spill fire area (determined from the volume of product released and the topography of the containment area), in square metres;
3. the method of foam application (fixed monitors or portable equipment); 66
4. the type of foam;
5. the foam application rate for type of foam and method of application, in litres per minute per square metre; and
6. the minimum foam application time, in minutes.

Calculate the total water flow requirements.

A.7.4.2

The total water flow requirements should be available for at least 1 h.

NOTE In the case of other operational spill fire events such as at pump manifolds etc., the determination of water requirements would be similar to the event given in A.7.4. Allowance could be made for cooling hose streams/reels and water for isolation, if required.

A.7.4.3

If stone ballast for the containment of operational spills is provided such that the volume of any anticipated spill can be completely contained within the voids, then the spill open surface area may be considered as (open) void area at the stone ballast surface, provided that the maintenance of these conditions are guaranteed.

The fire surface area may be considered as the (open) void area at the stone ballast surface and foam water requirements calculated as in A.7.4.1 and A.7.4.2.

NOTE It is important that allowance is made in the expanded foam application technique, since expanded foam is designed to float and flow over the surface of the flammable liquid and will not readily flow over the stone ballast. This can be accomplished by use of, for example, hand-held foam nozzles and oscillating foam monitors. If fixed foam pourers are used it may be necessary to increase the application rate of foam/water solution or the number of foam pourers, or both, to ensure adequate coverage of the stone ballast surface area.

Adequate underground drainage should be provided to rapidly clear the voids from any previous spills and water to maintain the operational spill capacity of the stone ballast voids. The capacity of the stone ballast voids should be designed to handle the anticipated operational spill during worst case conditions, namely during the design storm (generally the 2 year storm is assumed). (As this poses significant practical problems, it is not considered a viable option by the majority of oil industry members.)

67

Annex B
Design criteria for interceptors (gravity separators)

(informative)

B.1 General

From the results of experiments and from plant operating data, it has been determined that the design of waste water separators should be based on the rate of rise of oil globules that have an average diameter of 150 urn. This globule size, although somewhat arbitrary, has been adopted for design purposes because satisfactory oil removals are achieved when a particle of 150 urn diameter is used as a basis for design or investigation.

B.2 Design procedure

The vertical rate of rise, V_t, of an oil droplet in water is given by the formula

V_t = 1,962 × 10^–9 × Δσ × D²/η

Amdt 1; amdt 3

where

V_t is the vertical rate of rise, in metres per hour;

Δσ is the difference in densities between water and oil, in kilograms per cubic metre;

D is the diameter of the oil droplet, in micrometres; and

η is the dynamic viscosity of water, in pascal-seconds.

The interceptor should be so designed for a given water flow rate q that there is sufficient time for the oil globules to rise all the way from the bottom of the interceptor to the under-surface.

The design of the retention system around the spill origin and outlets should be able to cope even with the worst rainfall conditions and should therefore take into account the maximum rain intensity (this figure can be obtained from the Mean Annual Precipitation (MPA) map of the RSA), viz, 40 mm/h for both coastal and inland zones. Assuming that the rain water runs off as fast as it is deposited, the maximum runoff becomes

q = C.I.A/60000

where

q     is the runoff flow capacity, in cubic metres per minute;

C     is the runoff coefficient (e.g. 0,9 for concrete);

l     the rain intensity, in millimetres per hour; and

A     is the catchment area, in square metres.

68

The horizontal velocity, V_h, is given by

V_h = q / A_c

where

V_h     is the horizontal velocity, in metres per minute;

q     is the runoff flow capacity, in cubic metres per minute; and

A_c     is the cross-sectional area of the separator, in square metres.

An acceptable maximum horizontal velocity V_h, for the flow through an interceptor would be less than 0,91 m/min (3 ft/min or 55 m/h), or 15 V_t, whichever is the smaller.

The length of the separator, L, in metres, is given by

L = F (V_h/V_t) × d

where

F is a design factor (dimensionless); and

d is the depth of the separator, in metres.

The design factor F is the product of the short-circuiting factor, F_sc, which can be taken as 1,2, and the turbulence factor, F _t, which is a function of the ratio of V_h to V_t:

F = F_sc × F_t

The American Petroleum Institute gives the following recommended values of turbulence factors:

Amdt 1

Furthermore, a separator should be designed within the following limits:

1. a depth d of between 1 m (3ft) and 2,4 m (8ft);
2. a recommended depth-to-width ratio greater than 0,3 and less than 0,5 i.e. d = 0,3 W to 0,5 W, where W is the width of the separator; and
3. a width W of between 2 m (6 ft) and 20 m (6 m).

69

B.3 Example

A separator is to be designed to cater for runoff from a concrete area 50 m × 45 m = 2 250 m², assuming a maximum rain intensity of 40 mm/h. The design temperature is 10 °C, and waste water through the separator contains diesel with a density of 860 kg/m³ at 10 °C.

which is greater than 0,91 m/min, therefore use V_h = 0,91 m/min as a maximum.

To avoid excessively long separators, V_h should, in practice, be kept to a minimum. This can be done by increasing (within reason) the cross-sectional area of the separator.

70

By interpolation between the listed turbulence factors,

Therefore, the final dimensions of the separator would be:

71

Annex C
Examples of typical work permits

(informative)

C.1 Gas-free certificate

72

C.2 Example of permit for entry into a confined space

73

C.3 Example of a hot-work permit

74

75

76

C.4 Example of a general or cold-work permit

77

78

C.4 Example of a general or cold-work permit (concluded)

C.5 Example of an electrical work permit

79

Annex D

(informative)

Safety distances for LPG facilities

LPG tank installation

For the recommended installation and safety distances of LPG tanks, refer to SANS 10087-1 and SANS 10087-3.

Figure D.1 — Recommended safety distances for LPG facilities

80

Annex E
Bibliography

(informative)

NOTE Legislative bodies who wish to incorporate this part of the code of practice into any law in terms of Section 29 of the Standards Act, 1993, are requested to note that compliance with the international or foreign standards or publications listed here may not be enforceable under the incorporating law.

API RP 2030, Application of fixed water spray systems for fire protection in the petroleum and petrochemical industries.

Amdt 1; amdt 2

API RP 520-2, Sizing, selection and installation of pressure-relieving devices in refineries – Part 2: Installation.

Amdt 1

API Std 2510, Design and construction of LPG installations.

CKS 532, Fire extinguishing agent: aqueous-film-forming-foam concentrate.

NFPA 15, Standard for water spray fixed systems for fire protection.

Amdt 1

NFPA 22, Water tanks for private fire protection.

NFPA 30, Flammable and combustible liquids code.

NFPA 58, Storage and handling of liquefied petroleum gas code.

NFPA 69, Standard on explosion prevention systems.

Amdt 1

PD 5500, Specification for unfired fusion welded pressure vessels.

SANS 460, Plain-ended solid drawn copper tubes for potable water.

SANS 741, Industrial boots (including safety boots) with direct-vulcanized soles and heels.

SANS 809, Industrial body belts.

SANS 1151, Portable rechargeable fire extinguishers – Halogenated hydrocarbon type extinguishers.

SANS 1535, Glass-reinforced polyester-coated steel tanks for the underground storage of hydrocarbons and oxygenated solvents and intended for burial horizontally.

SANS 1774, Liquefied petroleum gases.

SANS 10019 (SABS 019), Transportable metal containers for compressed gas – Basic design, manufacture, use and maintenance.

81

SANS 10087-1, The handling, storage, distribution and maintenance of liquefied petroleum gas in domestic, commercial, and industrial installations – Part 1: Liquefied petroleum gas installations involving gas storage containers of individual water capacity not exceeding 500 L and a combined water capacity not exceeding 3 000 L per installation.

SANS 10087-3, The handling, storage, distribution and maintenance of liquefied petroleum gas in domestic, commercial, and industrial installations – Part 3: Liquefied petroleum gas installations involving storage vessels of individual water capacity exceeding 500 L.

SANS 10087-4 (SABS 087-4), The handling, storage, distribution and maintenance of liquefied petroleum gas in domestic, commercial and industrial installations – Part 4: Transportation of liquefied petroleum gas in bulk by road.

SANS 10089-3 (SABS 089-3), The petroleum industry – Part 3: The installation of underground storage tanks, pumps/dispensers and pipework at service stations and consumer installations.

SANS 10090, Community protection against fire.

SANS 10105-1, The use and control of fire-fighting equipment – Part 1: Portable and wheeled (mobile) fire extinguishers.

SANS 10105-2, The use and control of fire-fighting equipment – Part 2: Fire hose reels, hydrants and booster connections.

SANS 10119 (SABS 0119), Reduction of explosion hazards presented by electrical equipment – Segregation, ventilation and pressurization.

SANS 10131, Above-ground storage tanks for petroleum products.

Amdt 2

SANS 60079-10/IEC 60079-10, Electrical apparatus for explosive gas atmospheres – Part 10: Classification of hazardous areas.

SANS 60079-11/IEC 60079-11, Electrical apparatus for explosive gas atmosphere – Part 11: Classification of hazardous areas.

Amdt 1

UL 582⁾, Steel underground tanks for flammable and combustible liquids.

Amdt 2

UL 154²⁾, Carbon-dioxide fire extinguishers.

Amdt 2

Regulations for the harbours of the Republic of South Africa (published by Transnet).

South African private siding regulations (published by Transnet).

Transport provision and construction of private sidings (published by Transnet).

© Standards South Africa

2) UL standards are published by Underwriter’s Laboratories Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096 USA (www.ul.com).

Amdt 2

82